Surgical stapler end effector sled having cartridge wall support feature

ABSTRACT

A staple driver actuator for a surgical stapler includes a base having at least one bottom surface. The bottom surface defines a plane and is configured to slide longitudinally relative to a jaw of the surgical stapler. The staple driver actuator also includes a plurality of rails extending upwardly from the base. Each of the plurality of rails includes at least one cam surface, and each of the cam surfaces is inclined relative to the plane. The plurality of rails includes a laterally-opposed pair of outer rails and a laterally-opposed pair of inner rails. The staple driver actuator further includes a distal nose extending distally from at least a portion of the base and having at least one ledge surface. The ledge surface faces upwardly, is parallel to the plane, and is at least partially positioned distally relative to each of the outer and inner rails.

BACKGROUND

Examples of surgical instruments include surgical staplers, which may beconfigured for use in laparoscopic surgical procedures and/or opensurgical procedures. Some such staplers are operable to clamp down onlayers of tissue, cut through the clamped layers of tissue, and drivestaples through the layers of tissue to substantially seal the severedlayers of tissue together near the severed ends of the tissue layers.Examples of surgical staplers are disclosed in U.S. Pat. No. 7,404,508,entitled “Surgical Stapling and Cutting Device,” issued Jul. 29, 2008;U.S. Pat. No. 7,434,715, entitled “Surgical Stapling Instrument HavingMultistroke Firing with Opening Lockout,” issued Oct. 14, 2008; U.S.Pat. No. 7,721,930, entitled “Disposable Cartridge with Adhesive for Usewith a Stapling Device,” issued May 25, 2010; U.S. Pat. No. 8,408,439,entitled “Surgical Stapling Instrument with An Articulatable EndEffector,” issued Apr. 2, 2013; and U.S. Pat. No. 8,453,914, entitled“Motor-Driven Surgical Cutting Instrument with Electric ActuatorDirectional Control Assembly,” issued Jun. 4, 2013. The disclosure ofeach of the above-cited U.S. Patents is incorporated by reference hereinin its entirety.

While various kinds of surgical stapling instruments and associatedcomponents have been made and used, it is believed that no one prior tothe inventor(s) has made or used the invention described in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention,and, together with the general description of the invention given above,and the detailed description of the embodiments given below, serve toexplain the principles of the present invention.

FIG. 1 depicts a perspective view of an example of an articulatingsurgical stapling instrument;

FIG. 2 depicts a side view of the instrument of FIG. 1 ;

FIG. 3 depicts a perspective view of an opened end effector of theinstrument of FIG. 1 ;

FIG. 4A depicts a side cross-sectional view of the end effector of FIG.3 , taken along line 4-4 of FIG. 3 , with a firing beam in a proximalposition;

FIG. 4B depicts a side cross-sectional view of the end effector of FIG.3 , taken along line 4-4 of FIG. 3 , with the firing beam in a distalposition;

FIG. 5 depicts an end cross-sectional view of the end effector of FIG. 3, taken along line 5-5 of FIG. 3 ;

FIG. 6 depicts an exploded perspective view of the end effector of FIG.3 ;

FIG. 7 depicts a perspective view of the end effector of FIG. 3 ,positioned at tissue and having been actuated once in the tissue;

FIG. 8 depicts a perspective view of an example of a wedge sled foractuating staple drivers of the instrument of FIG. 1 , showing the wedgesled having a cartridge wall support feature and multiple surfacefinishes;

FIG. 9 depicts a side view of the wedge sled of FIG. 8 ;

FIG. 10 depicts an end cross-sectional view of the end effector of FIG.3 with the wedge sled of FIG. 8 captured between a cartridge body and acartridge tray of a staple cartridge of the end effector;

FIG. 11 depicts a perspective view of another example of a wedge sledfor actuating the staple drivers of the instrument of FIG. 1 , showingthe wedge sled having a cartridge wall support feature, a staple driversupport feature, a tapered distal end, and multiple surface finishes;

FIG. 12 depicts a side view of the wedge sled of FIG. 11 ;

FIG. 13 depicts an end cross-sectional view of the end effector of FIG.3 with the wedge sled of FIG. 11 captured between the cartridge body andthe cartridge tray of the staple cartridge of the end effector;

FIG. 14A depicts a side cross-sectional view of the end effector of FIG.3 , with the wedge sled of FIG. 11 captured between the cartridge bodyand the cartridge tray of the staple cartridge of the end effector,showing the wedge sled in a proximal position;

FIG. 14B depicts a side cross-sectional view of the end effector of FIG.3 , with the wedge sled of FIG. 11 captured between the cartridge bodyand the cartridge tray of the staple cartridge of the end effector,showing a distal chamfer of the wedge sled partially lifting acorresponding staple driver during distal translation of the wedge sled;

FIG. 14C depicts a side cross-sectional view of the end effector of FIG.3 , with the wedge sled of FIG. 11 captured between the cartridge bodyand the cartridge tray of the staple cartridge of the end effector,showing a top surface of a base of the wedge sled vertically supportingthe corresponding staple driver during distal translation of the wedgesled;

FIG. 14D depicts a side cross-sectional view of the end effector of FIG.3 , with the wedge sled of FIG. 11 captured between the cartridge bodyand the cartridge tray of the staple cartridge of the end effector,showing a cam surface of a sled rail of the wedge sled fully lifting thecorresponding staple driver during distal translation of the wedge sled;

FIG. 15 depicts an end cross-sectional view of the end effector of FIG.3 with another exemplary wedge sled captured between the cartridge bodyand the cartridge tray of the staple cartridge of the end effector,showing the wedge sled having toed-in inner and outer sled rails andundercuts;

FIG. 16 depicts an end cross-sectional view of the end effector of FIG.3 with another exemplary wedge sled captured between the cartridge bodyand the cartridge tray of the staple cartridge of the end effector,showing the wedge sled having toed-in inner and outer sled rails;

FIG. 17 depicts an end cross-sectional view of the end effector of FIG.3 with another exemplary wedge sled captured between the cartridge bodyand the cartridge tray of the staple cartridge of the end effector,showing the wedge sled having toed-in inner sled rails;

FIG. 18 depicts a cross-sectional view of another exemplary wedge sledhaving a V-shaped base;

FIG. 19 depicts a cross-sectional view of another exemplary wedge sledhaving a bifurcated central nose;

FIG. 20 depicts an end cross-sectional view of the end effector of FIG.3 with an exemplary staple cartridge removably installed into a channelof a lower jaw of the end effector, showing the staple cartridge havingvarious biasing features; and

FIG. 21 depicts an end cross-sectional view of the end effector of FIG.3 with an exemplary staple cartridge removably installed into a channelof a lower jaw of the end effector, showing the staple cartridge havinga cartridge tray with protrusions for decreasing a tissue gap between anupper deck of the staple cartridge and an inner surface of the anvil.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the invention may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presentinvention, and together with the description serve to explain theprinciples of the invention; it being understood, however, that thisinvention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention shouldnot be used to limit the scope of the present invention. Other examples,features, aspects, embodiments, and advantages of the invention willbecome apparent to those skilled in the art from the followingdescription, which is by way of illustration, one of the best modescontemplated for carrying out the invention. As will be realized, theinvention is capable of other different and obvious aspects, all withoutdeparting from the invention. Accordingly, the drawings and descriptionsshould be regarded as illustrative in nature and not restrictive.

I. EXAMPLE OF SURGICAL STAPLER

FIGS. 1-7 depict an example of a surgical stapling and severinginstrument (10) that is sized for insertion, in a nonarticulated stateas depicted in FIG. 1 , through a trocar cannula, thoracotomy, or otherincision to a surgical site in a patient for performing a surgicalprocedure. Instrument (10) of the present example includes a handleportion (20) connected to a shaft (22). Shaft (22) distally terminatesin an articulation joint (11), which is further coupled with an endeffector (12). It should be understood that terms such as “proximal” and“distal” are used herein with reference to a clinician gripping handleportion (20) of instrument (10). Thus, end effector (12) is distal withrespect to the more proximal handle portion (20).

Once articulation joint (11) and end effector (12) are inserted into thepatient, articulation joint (11) may be remotely articulated, asdepicted in phantom in FIG. 1 , by an articulation control (13), suchthat end effector (12) may be deflected from the longitudinal axis (LA)of shaft (22) at a desired angle (a). By way of example only,articulation joint (11) and/or articulation control (13) may beconstructed and operable in accordance with at least some of theteachings of U.S. Pat. No. 9,186,142, entitled “Surgical Instrument EndEffector Articulation Drive with Pinion and Opposing Racks,” issued onNov. 17, 2015, the disclosure of which is incorporated by referenceherein in its entirety; and/or U.S. Pat. No. 9,795,379, entitled“Surgical Instrument with Multi-Diameter Shaft,” issued Oct. 24, 2017,the disclosure of which is incorporated by reference herein in itsentirety. Other suitable forms that articulation joint (11) andarticulation control (13) may take will be apparent to those skilled inthe art in view of the teachings herein.

End effector (12) of the present example includes a lower jaw (16) andan upper jaw in the form of a pivotable anvil (18). By way of exampleonly, lower jaw (16) may be constructed and operable in accordance withat least some of the teachings of U.S. Pat. No. 9,808,248, entitled“Installation Features for Surgical Instrument End Effector Cartridge,”issued Nov. 7, 2017, the disclosure of which is incorporated byreference herein in its entirety. Anvil (18) may be constructed andoperable in accordance with at least some of the teachings of at leastsome of the teachings of U.S. Pat. No. 10,092,292, entitled “StapleForming Features for Surgical Stapling Instrument,” issued Oct. 9, 2018,the disclosure of which is incorporated by reference herein in itsentirety. Other suitable forms that lower jaw (16) and anvil (18) maytake will be apparent to those skilled in the art in view of theteachings herein.

Handle portion (20) includes a pistol grip (24) and a closure trigger(26). Closure trigger (26) is pivotable toward pistol grip (24) to causeclamping, or closing, of the anvil (18) toward lower jaw (16) of endeffector (12). Such closing of anvil (18) is provided through a closuretube (32) and a closure ring (33), which both longitudinally translaterelative to handle portion (20) in response to pivoting of closuretrigger (26) relative to pistol grip (24). Closure tube (32) extendsalong the length of shaft (22); and closure ring (33) is positioneddistal to articulation joint (11). Articulation joint (11) is operableto transmit longitudinal movement from closure tube (32) to closure ring(33).

Handle portion (20) also includes a firing trigger (28). An elongatemember (not shown) longitudinally extends through shaft (22) andcommunicates a longitudinal firing motion from handle portion (20) to afiring beam (14) in response to actuation of firing trigger (28). Thisdistal translation of firing beam (14) causes the stapling and severingof tissue clamped in end effector (12), as will be described in greaterdetail below. Thereafter, triggers (26, 28) may be released to releasethe tissue from end effector (12).

As best seen in FIGS. 4A-4B, firing beam (14) of the present exampleincludes a transversely oriented upper pin (38), a firing beam cap (44),a transversely oriented middle pin (46), and a distally presentedcutting edge (48). Upper pin (38) is positioned and translatable withina longitudinal anvil slot (42) of anvil (18). Firing beam cap (44)slidably engages a lower surface of lower jaw (16) by having firing beam(14) extend through lower jaw slot (45) (shown in FIG. 4B) that isformed through lower jaw (16). Middle pin (46) slidingly engages a topsurface of lower jaw (16), cooperating with firing beam cap (44).Thereby, firing beam (14) affirmatively spaces end effector (12) duringfiring. By way of example only, firing beam (14) and/or associatedlockout features may be constructed and operable in accordance with atleast some of the teachings of U.S. Pat. No. 9,717,497, entitled“Lockout Feature for Movable Cutting Member of Surgical Instrument,”issued Aug. 1, 2017, the disclosure of which is incorporated byreference herein in its entirety. Other suitable forms that firing beam(14) may take will be apparent to those skilled in the art in view ofthe teachings herein.

FIG. 3 shows firing beam (14) of the present example proximallypositioned and anvil (18) pivoted to an open position, allowing anunspent staple cartridge (37) to be removably installed into a channelof lower jaw (16). As best seen in FIGS. 5-6 , staple cartridge (37) ofthis example includes a cartridge body (70), which presents an upperdeck (72) and is coupled with a lower cartridge tray (74). As best seenin FIG. 3 , a vertical slot (49) is formed through part of staplecartridge (37). Three rows of staple apertures (51) are formed throughupper deck (72) on one side of vertical slot (49), with another set ofthree rows of staple apertures (51) being formed through upper deck (72)on the other side of vertical slot (49). Of course, any other suitablenumber of staple rows (e.g., two rows, four rows, any other number) maybe provided. Referring back to FIGS. 4A-6 , a wedge sled (41) and aplurality of staple drivers (43) are captured between cartridge body(70) and tray (74), with wedge sled (41) being located proximal tostaple drivers (43) when staple cartridge (37) is in an pre-fired (or“unspent”) state. Wedge sled (41) is movable longitudinally withinstaple cartridge (37); while staple drivers (43) are movable verticallywithin staple cartridge (37). Staples (47) are also positioned withincartridge body (70), above corresponding staple drivers (43). Inparticular, each staple (47) is driven vertically within cartridge body(70) by a staple driver (43) to drive staple (47) out through anassociated staple aperture (51). As best seen in FIGS. 4A-4B and 6 ,wedge sled (41) presents inclined cam surfaces that urge staple drivers(43) upwardly as wedge sled (41) is driven distally through staplecartridge (37).

By way of example only, staple cartridge (37) may be constructed andoperable in accordance with at least some of the teachings of U.S. Pat.No. 9,517,065, entitled “Integrated Tissue Positioning and Jaw AlignmentFeatures for Surgical Stapler,” issued Dec. 13, 2016, the disclosure ofwhich is incorporated by reference herein in its entirety. Othersuitable forms that staple cartridge (37) may take will be apparent tothose skilled in the art in view of the teachings herein.

With end effector (12) closed as depicted in FIGS. 4A-4B by distallyadvancing closure tube (32) and closure ring (33), firing beam (14) isthen advanced in engagement with anvil (18) by having upper pin (38)enter longitudinal anvil slot (42). A pusher block (80) (shown in FIG. 5) located at the distal end of firing beam (14) is configured to engagewedge sled (41) such that wedge sled (41) is pushed distally by pusherblock (80) as firing beam (14) is advanced distally through staplecartridge (37) when firing trigger (28) is actuated. During such firing,cutting edge (48) of firing beam (14) enters vertical slot (49) ofstaple cartridge (37), severing tissue clamped between staple cartridge(37) and anvil (18). As shown in FIGS. 4A-4B, middle pin (46) and pusherblock (80) together actuate staple cartridge (37) by entering intovertical slot (49) within staple cartridge (37), driving wedge sled (41)into upward camming contact with staple drivers (43) that in turn drivestaples (47) out through staple apertures (51) and into forming contactwith staple forming pockets (53) (shown in FIG. 3 ) on the inner surfaceof anvil (18). FIG. 4B depicts firing beam (14) fully distallytranslated after completing severing and stapling of tissue. It shouldbe understood that staple forming pockets (53) are intentionally omittedfrom the view in FIGS. 4A-4B; but staple forming pockets (53) are shownin FIG. 3 . It should also be understood that anvil (18) isintentionally omitted from the view in FIG. 5 .

FIG. 7 shows end effector (12) having been actuated through a singlestroke through layers (L₁, L₂) of tissue (T). As shown, cutting edge(48) (obscured in FIG. 7 ) has cut through tissue (T), while stapledrivers (43) have driven three alternating rows of staples (47) throughthe tissue (T) on each side of the cut line produced by cutting edge(48). Staples (47) are all oriented substantially parallel to the cutline in this example, though it should be understood that staples (47)may be positioned at any suitable orientations. In the present example,end effector (12) is withdrawn from the trocar or incision after thefirst stroke is complete, spent staple cartridge (37) is replaced with anew staple cartridge, and end effector (12) is then again insertedthrough the trocar or incision to reach the stapling site for furthercutting and stapling. This process may be repeated until the desirednumber of cuts and staples (47) have been provided. Anvil (18) may needto be closed to facilitate insertion and withdrawal through the trocar;and anvil (18) may need to be opened to facilitate replacement of staplecartridge (37).

In some versions, instrument (10) provides motorized control of firingbeam (14). By way of example only, such motorization may be provided inaccordance with at least some of the teachings of U.S. Pat. No.9,622,746, entitled “Distal Tip Features for End Effector of SurgicalInstrument,” issued Apr. 18, 2017, the disclosure of which isincorporated by reference herein in its entirety; and/or U.S. Pat. No.8,210,411, entitled “Motor-Driven Surgical Instrument,” issued Jul. 3,2012, the disclosure of which is incorporated by reference herein in itsentirety. Other suitable components, features, and configurations forproviding motorization of firing beam (14) will be apparent to thoseskilled in the art in view of the teachings herein. It should also beunderstood that some other versions may provide manual driving of firingbeam (14), such that a motor may be omitted.

II. EXEMPLARY SLED HAVING CARTRIDGE WALL SUPPORT FEATURE AND MULTIPLESURFACE FINISHES

In some instances, it may be desirable to provide a wedge sled that isconfigured to provide rigidity to staple cartridge (37) by supportingand/or stabilizing the walls of cartridge body (70) adjacent to thewedge sled to thereby promote alignment between staple apertures (51)and the corresponding staple forming pockets (53) during clamping oftissue between staple cartridge (37) and anvil (18) and/or duringfiring. In addition or alternatively, it may be desirable to provide awedge sled having multiple distinct surface finishes (also referred toas “surface textures” or “surface topographies”). Such multiple distinctsurface finishes may allow a wedge sled manufactured via a process whichimparts an initial, relatively rough surface finish to the surfaces ofthe entire wedge sled to have select surfaces provided with a final,relatively smooth surface finish so that the select surfaces maysmoothly interact with corresponding portions of staple cartridge (37),such as staple drivers (43). FIGS. 8-10 show an exemplary wedge sled(110) which provides such functionalities. Wedge sled (110) is similarto wedge sled (41) described above except as otherwise described below.For example, wedge sled (110) occupies the same amount of spacelongitudinally within staple cartridge (37) as wedge sled (41), makingwedge sled (110) substantially interchangeable with wedge sled (41).

Wedge sled (110) of this example comprises a base including a baseplatform (112) and a central raised platform (114) extending upwardlyfrom base platform (112). In the example shown, base platform (112) hasa substantially flat bottom surface (116) defining a horizontal planeand configured to slide longitudinally along tray (74) while wedge sled(110) moves longitudinally through staple cartridge (37). Base platform(112) also has a laterally-opposed pair of substantially flat topsurfaces (118) parallel to bottom surface (116), and raised platform(114) similarly has a laterally-opposed pair of substantially flat topsurfaces (120) parallel to bottom surface (116). As best shown in FIG.10 , top surfaces (118, 120) are configured to confront and/or slidablycontact or otherwise engage respective bottom surfaces of correspondingwalls (71) of cartridge body (70) to thereby vertically support thecorresponding walls (71) while wedge sled (110) moves longitudinallythrough staple cartridge (37).

The base of the present version also includes a lower chamfer (122)inclined upwardly and distally from a distal end of bottom surface (116)to outer and inner distal ends of base platform (112); a pair of outerupper chamfers (124) inclined downwardly and distally from respectivedistal ends of top surfaces (118) of base platform (112) to the outerdistal ends of base platform (112); and a pair of inner upper chamfers(126) inclined downwardly and distally from respective distal ends oftop surfaces (120) of raised platform (114) to the inner distal ends ofbase platform (112). Chamfers (122, 124, 126) may also be referred to as“tapered surfaces” or “bevels.” Lower chamfer (122) may extend across awidth of base platform (112) and may have a length greater than athickness of base platform (112) (e.g., between bottom surface (116) andeither top surface (118)). Likewise, outer upper chamfers (124) may eachhave a length greater than a thickness of base platform (112). Lowerchamfer (122) may be configured to promote unimpeded longitudinalmovement of wedge sled (110) through staple cartridge (37) in the distaldirection by reducing the likelihood of the distal end of base platform(112) catching, or otherwise being obstructed by, tray (74). Forexample, lower chamfer (122) may urge tray (74) (which may beconstructed of a flexible material) slightly downwardly away from thebottom surfaces of walls (71) of cartridge body (70) as wedge sled (110)is driven distally through staple cartridge (37). In some versions, anyone or more of chamfers (122, 124, 126) may be omitted. For example, anyone or more of chamfers (122, 124, 126) may be replaced by one or morerespective fillets.

Wedge sled (110) further comprises a laterally-opposed pair of outersled rails (130) extending upwardly from base platform (112), and alaterally-opposed pair of inner sled rails (132) extending upwardly fromboth base platform (112) and raised platform (114). Sled rails (130,132) may also be referred to as “cam ramps” or “cam wedges.” Sled rails(130, 132) of the present version extend substantially straight andupright from the respective top surfaces (118, 120) of base platform(112) and raised platform (114), such that sled rails (130, 132) areperpendicularly oriented relative to the horizontal plane and parallelto a vertical-longitudinal plane. In the example shown, inner sled rails(132) are laterally spaced apart from adjacent outer sled rails (130) todefine top surfaces (118) of base platform (112). In this regard, topsurfaces (118) of base platform (112) each extend at least partiallyalong the lengths of sled rails (130, 132), and top surfaces (120) ofraised platform (114) each extend at least partially along the length ofthe respective inner sled rail (132). Outer sled rails (130) of thepresent version each have a first height relative to bottom surface(116) of base platform (112), while inner sled rails (132) each have asecond height relative to bottom surface (116) of base platform (112)that is less than the first height. Also in the example shown, outer andinner sled rails (130, 132) each terminate proximally at a samelongitudinal position (e.g., at a proximal end of base platform (112)),while outer sled rails (130) each terminate distally at a firstlongitudinal position and inner sled rails (132) each terminate distallyat a second longitudinal position that is distal relative to the firstlongitudinal position, such that outer sled rails (130) each have afirst length and inner sled rails (132) each have a second length thatis greater than the first length. Thus, the distal ends of outer sledrails (130) are aligned with each other in the longitudinal direction,and the distal ends of inner sled rails (132) are aligned with eachother and offset from the distal ends of outer sled rails (130) in thelongitudinal direction.

As best shown in FIG. 10 , sled rails (130, 132) are configured to bereceived within corresponding longitudinally-extending slots (73) ofcartridge body (70), and to slidably contact or otherwise engagerespective side surfaces of corresponding walls (71) of cartridge body(70) to thereby horizontally stabilize walls (71) while wedge sled (110)moves longitudinally through staple cartridge (37). For example, outerand inner sled rails (130, 132) may inhibit laterally inward and/orlaterally outward deflection (e.g., bending) of walls (71). In thisregard, sled rails (130, 132) may each have a thickness equal to orslightly less than a width of the corresponding slot (73). In someversions, sled rails (130, 132) may additionally or alternatively beconfigured to slidably contact or otherwise engage respective upper slotsurfaces of corresponding slots (73) of cartridge body (70) to therebyvertically support upper deck (72) while wedge sled (110) moveslongitudinally through staple cartridge (37).

Each sled rail (130, 132) of wedge sled (110) presents one or morerespective inclined cam surfaces (140, 142, 144, 146) for lifting stapledrivers (43) upwardly as wedge sled (110) is driven distally throughstaple cartridge (37) to drive the corresponding staples (47) outthrough the corresponding staple apertures (51). In the example shown,each outer sled rail (130) includes a leading cam surface (140) orientedat a first angle relative to the horizontal plane defined by bottomsurface (116) and a trailing cam surface (142) oriented at a secondangle relative to the horizontal plane, such that outer sled rails (130)have a same side elevational profile as each other. Likewise, each innersled rail (132) includes a leading cam surface (144) oriented at thefirst angle relative to the horizontal plane and a trailing cam surface(146) oriented at a third angle relative to the horizontal plane, suchthat inner sled rails (132) have a same side elevational profile as eachother and a different elevational profile from that of outer sled rails(130). Thus, wedge sled (110) may be substantially symmetric about thevertical-longitudinal plane, at least with respect to the configurationsof sled rails (130, 132).

In the present version, the first angle is greater than the secondangle, which is greater than the third angle. Alternatively, any othersuitable relative angles may be used. In the example shown, upperchamfers (124, 126) are also oriented at the first angle relative to thehorizontal plane such that each leading cam surface (140) of outer sledrails (130) is seamlessly contiguous with the respective outer upperchamfer (124) (and has an overlapping side elevational profiletherewith) to collectively define a single continuous surface, and suchthat each leading cam surface (144) of inner sled rails (132) isseamlessly contiguous with the respective inner upper chamfer (126) (andhas an overlapping side elevational profile therewith) to collectivelydefine another single continuous surface.

Wedge sled (110) further comprises a central nose (150) extendingupwardly from raised platform (114) between inner sled rails (132) andalso extending distally from both raised platform (114) and baseplatform (112) to a distal tip (152). In the example shown, central nose(150) is laterally spaced apart from each inner sled rail (132) todefine top surfaces (120) of raised platform (114). More particularly,central nose (150) is equally spaced apart from inner sled rails (132).Central nose (150) of the present version includes a lower portion (154)extending distally from both base platform (112) and raised platform(114) to distal tip (152), and an upper portion (156) extending upwardlyfrom both raised platform (114) and lower portion (154).

As best shown in FIG. 9 , lower portion (154) of central nose (150) ofthe present version includes a tapered bottom surface (160) inclineddownwardly and proximally from distal tip to lower chamfer (122) of baseplatform (112). Tapered bottom surface (160) may be configured topromote unimpeded longitudinal movement of wedge sled (110) throughstaple cartridge (37) in the distal direction by reducing the likelihoodof distal tip (152) catching, or otherwise being obstructed by, tray(74). For example, tapered bottom surface (160) may urge tray (74)(which may be constructed of a flexible material) slightly downwardlyaway from the bottom surfaces of walls (71) of cartridge body (70) aswedge sled (110) is driven distally through staple cartridge (37). Inthe example shown, tapered bottom surface (160) is oriented at a sameangle relative to the horizontal plane defined by bottom surface (116)as lower chamfer (122) such that tapered bottom surface (160) isseamlessly contiguous with lower chamfer (122) to collectively define asingle continuous chamfer for further promoting unimpeded longitudinalmovement of wedge sled (110) through staple cartridge (37) in the distaldirection. In some versions, tapered bottom surface (160) may beomitted. For example, tapered bottom surface (160) may be replaced byone or more respective fillets.

Upper portion (156) of central nose (150) of the present version issubstantially perpendicular to the horizontal plane defined by bottomsurface (116). As shown, upper portion (156) extends longitudinally froma proximal end of raised platform (114) to distal tip (152), such thatupper portion (156) is at least partially positioned distally relativeto a distal end of base platform (112) and relative to distal ends ofsled rails (130, 132), and such that upper portion (156) extends atleast partially along the length of each sled rail (130, 132).

In the example shown, lower portion (154) of central nose (150) extendslaterally outwardly relative to upper portion (156) on opposing sides ofupper portion (156) to define a laterally-opposed pair ofupwardly-facing ledge surfaces (162) extending longitudinally fromrespective top surfaces (120) of raised platform (114) to distal tip(152). More particularly, ledge surfaces (162) are substantially flat,parallel to the horizontal plane defined by bottom surface (116), andpositioned at a same height as top surfaces (120) of raised platform(114) relative to bottom surface (116), such that ledge surfaces (162)are seamlessly contiguous with respective top surfaces (120) of raisedplatform (114) to collectively define respective single continuoussurfaces. As shown, each ledge surface (162) is at least partiallypositioned distally relative to a distal end of base platform (112) andrelative to distal ends of sled rails (130, 132).

As best shown in FIG. 10 , central nose (150) is configured to be atleast partially received within vertical slot (49) of staple cartridge(37). In some versions, central nose (150) is configured to slidablycontact or otherwise engage inner walls (71) of cartridge body (70) tothereby vertically support and/or horizontally stabilize inner walls(71) while wedge sled (110) moves longitudinally through staplecartridge (37). In this regard, ledge surfaces (162) of the presentversion confront and slidably contact or otherwise engage respectivelower surfaces of inner walls (71) to thereby vertically support innerwalls (71) while wedge sled (110) moves longitudinally through staplecartridge (37). In addition, upper portion (156) of the present versionslidably contacts or otherwise engages laterally inward surfaces ofinner walls (71) to thereby horizontally stabilize inner walls (71)while wedge sled (110) moves longitudinally through staple cartridge(37). For example, upper portion (156) may inhibit laterally inwarddeflection (e.g., bending) of inner walls (71). In this regard, upperportion (156) may have a thickness equal to or slightly less than awidth of vertical slot (49), while lower portion (154) may have athickness greater than the width of vertical slot (49).

Since each ledge surface (162) of central nose (150) is at leastpartially positioned distally relative to distal ends of sled rails(130, 132), ledge surfaces (162) may vertically support inner walls (71)of cartridge body (70) at longitudinal positions that are distalrelative to sled rails (130, 132) while wedge sled (110) moveslongitudinally through staple cartridge (37). Likewise, since upperportion (156) is at least partially positioned distally relative todistal ends of sled rails (130, 132), upper portion (156) mayhorizontally stabilize inner walls (71) of cartridge body (70) atlongitudinal positions that are distal relative to sled rails (130, 132)while wedge sled (110) moves longitudinally through staple cartridge(37). In this manner, central nose (150) may provide vertical supportand/or horizontal stability to cartridge body (70) at longitudinalpositions corresponding to each staple aperture (51) along the length ofcartridge body (70) in advance of (e.g., at least immediately prior to)the corresponding sled rail (130, 132) lifting the corresponding stapledriver (43) to drive the corresponding staple (47) out through stapleaperture (51). By providing vertical support and/or horizontal stabilityto cartridge body (70) at such longitudinal positions in advance oflifting staple drivers (43) to drive staples (47) out through stapleapertures (51) at such longitudinal positions, central nose (150) maypromote proper alignment of each staple aperture (51) with thecorresponding staple forming pocket (53) on the inner surface of anvil(18) in advance of deploying and forming each staple (47). For example,central nose (150) may promote vertical and/or angular alignment of eachstaple aperture (51) with the corresponding staple forming pocket (53)by assisting in maintaining upper deck (72) substantially parallel tothe inner surface of anvil (18) having staple forming pockets (53),and/or by inhibiting lateral deflection of inner walls (71) which mightotherwise cause staple apertures (51) to be angled (e.g., laterallyinwardly or laterally outwardly) relative to the corresponding stapleforming pocket (53).

Moreover, since top surfaces (118, 120) of base platform (112) andraised platform (114) each extend at least partially along the length ofthe respective sled rail (130, 132), top surfaces (118, 120) mayvertically support corresponding walls (71) of cartridge body (70) atthe same longitudinal positions at which sled rails (130, 132) arelocated while wedge sled (110) moves longitudinally through staplecartridge (37). In this manner, base platform (112) and/or raisedplatform (114) may provide vertical support to cartridge body (70) atlongitudinal positions corresponding to each staple aperture (51) alongthe length of cartridge body (70) substantially contemporaneously with(e.g., during at least a portion of the duration of) the correspondingsled rail (130, 132) lifting the corresponding staple driver (43) todrive the corresponding staple (47) out through staple aperture (51).

By providing vertical support to cartridge body (70) at suchlongitudinal positions substantially contemporaneously with liftingstaple drivers (43) to drive staples (47) out through staple apertures(51) at such longitudinal positions, base platform (112) and/or raisedplatform (114) may promote proper alignment of each staple aperture (51)with the corresponding staple forming pocket (53) on the inner surfaceof anvil (18) while deploying and forming each staple (47). For example,base platform (112) and/or raised platform (114) may promote verticaland/or angular alignment of each staple aperture (51) with thecorresponding staple forming pocket (53) by assisting in maintainingupper deck (72) substantially parallel to the inner surface of anvil(18) having staple forming pockets (53). Since top surfaces (120) ofraised platform (114) are seamlessly contiguous with respective ledgesurfaces (162), central nose (150) and raised platform (114) maycooperatively promote continuous proper alignment of each stapleaperture (51) with the corresponding staple forming pocket (53) on theinner surface of anvil (18) from at least immediately prior to deployingand forming each staple (47) to completion of deploying and forming eachstaple (47).

Additionally, since upper portion (156) of central nose (150) extends atleast partially along the length of each sled rail (130, 132), upperportion (156) may horizontally stabilize inner walls (71) of cartridgebody (70) at the same longitudinal positions at which sled rails (130,132) are located while wedge sled (110) moves longitudinally throughstaple cartridge (37). In this manner, central nose (150) may providehorizontal stability to cartridge body (70) at longitudinal positionscorresponding to each staple aperture (51) along the length of cartridgebody (70) substantially contemporaneously with (e.g., during at least aportion of the duration of) the corresponding sled rail (130, 132)lifting the corresponding staple driver (43) to drive the correspondingstaple (47) out through staple aperture (51). By providing horizontalstability to cartridge body (70) at such longitudinal positionssubstantially contemporaneously with lifting staple drivers (43) todrive staples (47) out through staple apertures (51) at suchlongitudinal positions, central nose (150) may promote proper alignmentof each staple aperture (51) with the corresponding staple formingpocket (53) on the inner surface of anvil (18) while deploying andforming each staple (47). For example, central nose (150) may promotevertical and/or angular alignment of each staple aperture (51) with thecorresponding staple forming pocket (53) by inhibiting lateraldeflection of inner walls (71) which might otherwise cause stapleapertures (51) to be angled (e.g., laterally inwardly or laterallyoutwardly) relative to the corresponding staple forming pocket (53). Asdiscussed above, sled rails (130, 132) may themselves horizontallystabilize corresponding walls (71) of cartridge body (70) at theirrespective longitudinal positions, and thus may also promote verticaland/or angular alignment of each staple aperture (51) with thecorresponding staple forming pocket (53) by inhibiting lateraldeflection of inner walls (71) which might otherwise cause stapleapertures (51) to be angled (e.g., laterally inwardly or laterallyoutwardly) relative to the corresponding staple forming pocket (53).Therefore, central nose (150) and sled rails (130, 132) maycooperatively provide horizontal stability to cartridge body (70) at therespective longitudinal positions of each sled rail (130, 132) whilewedge sled (110) moves longitudinally through staple cartridge (37). Itshould be understood that anvil (18) is intentionally omitted from theview in FIG. 10 .

Wedge sled (110) may be formed of any suitable material or combinationof materials, including but not limited to metallic materials such asstainless steel (e.g., hardened stainless steel) or titanium. In someversions, wedge sled (110) may be manufactured via a metal injectionmolding (MIM) process. It will be appreciated that such a MIM processmay provide wedge sled (110) with improved compression support andreduced lateral deflection, and may enable wedge sled (110) to provideimproved vertical support and/or horizontal stability to cartridge body(70) during use (e.g., clamping and/or firing), as compared to a wedgesled (110) formed of a plastic material, for example. Such a MIM processmay include molding wedge sled (110) as a single unitary piece from aliquid MIM feedstock mix of metal powder and binder, for example. TheMIM process may further include subjecting wedge sled (110) to varioustypes of conditioning, including but not limited to cleaning, thermaldebinding, and/or sintering.

In any event, after the MIM process is complete, all surfaces of wedgesled (110) may have an initial (e.g., raw MIM) surface finish, includingcam surfaces (140, 142, 144, 146) of sled rails (130, 132). Such aninitial surface finish may be rough, abrasive, and/or granular, and maygenerally be similar to the texture of pitted sandpaper. Thus, selectsurfaces of wedge sled (110) may be further conditioned to refine orotherwise remove the initial surface finish from the select surfaces andprovide the select surfaces with a final surface finish that isrelatively smoother (e.g., finer, more polished) than the initialsurface finish. For example, cam surfaces (140, 142, 144, 146) of sledrails (130, 132) may be machined to remove the initial surface finishfrom cam surfaces (140, 142, 144, 146) and provide cam surfaces (140,142, 144, 146) with such a final surface finish. The final surfacefinish of cam surfaces (140, 142, 144, 146) may promote reduced frictionand smooth interaction between cam surfaces (140, 142, 144, 146) andstaple drivers (43) and thereby minimize wearing of the portions ofstaple drivers (43) contacted by cam surfaces (140, 142, 144, 146).

While the select surfaces provided with the final surface finish havebeen described in the form of cam surfaces (140, 142, 144, 146), it willbe appreciated that any other surfaces of wedge sled (110) mayadditionally or alternatively be provided with the final surface finish.For example, bottom surface (116) may be provided with the final surfacefinish to promote reduced friction and smooth interaction between bottomsurface (116) and tray (74).

In some versions, the remaining, non-select surfaces of wedge sled (110)may not be further conditioned such that the initial surface finish mayremain on the non-select surfaces during use (e.g., clamping and/orfiring). For example, top surfaces (118, 120) of base platform (112) andraised platform (114) and/or ledge surfaces (162) of central nose (150)may retain the initial surface finish. As another example, every surfaceof wedge sled (110) other than cam surfaces (140, 142, 144, 146) of sledrails (130, 132) may retain the initial surface finish. Thus, the selectsurfaces of wedge sled (110) may have the final surface finish while thenon-select surfaces of wedge sled (110) may have the initial surfacefinish, such that wedge sled (110) may have at least two distinctsurface finishes.

The select and non-select surfaces may be determined based on theparticular components of staple cartridge (37) and/or firing beam (14)with which each individual surface of wedge sled (110) interacts. Inthis regard, the final surface finish may be more desirable for surfacesof wedge sled (110) which interact with certain predetermined componentsof staple cartridge (37) and/or firing beam (14) than others. Forexample, cam surfaces (140, 142, 144, 146) of sled rails (130, 132) maybe selected to receive the final surface finish based on theirinteraction with staple drivers (43), while the remaining surfaces ofsled rails (130, 132), top surfaces (118) of base platform (112), topsurfaces (120) of raised platform (114), and/or ledge surfaces (162) ofcentral nose (150) may not be selected to receive the final surfacefinish based on their interaction with cartridge body (70). As anotherexample, bottom surface (116) may be selected to receive the finalsurface finish based on its interaction with tray (74), while a proximalend surface of wedge sled (110) may not be selected to receive the finalsurface finish based on its interaction with pusher block (80).

III. EXEMPLARY SLED HAVING CARTRIDGE WALL SUPPORT FEATURE, STAPLE DRIVERSUPPORT FEATURE, TAPERED DISTAL END, AND MULTIPLE SURFACE FINISHES

In some instances, it may be desirable to provide a wedge sled that isconfigured to support staple drivers (43) prior to fully lifting stapledrivers (43) to drive the corresponding staples (47) out through thecorresponding staple apertures (51), to thereby promote alignmentbetween staple drivers (43) and the corresponding staple forming pockets(53) during firing. In addition or alternatively, it may be desirable toprovide a wedge sled that is configured to provide rigidity to staplecartridge (37) and/or that has multiple distinct surface finishes (alsoreferred to as “surface textures” or “surface topographies”) asdiscussed above with respect to wedge sled (110). FIGS. 11-13 show anexemplary wedge sled (210) which provides such functionalities. Wedgesled (210) is similar to wedge sled (110) described above except asotherwise described below. For example, wedge sled (210) occupies thesame amount of space longitudinally within staple cartridge (37) aswedge sleds (41, 110), making wedge sled (210) substantiallyinterchangeable with wedge sleds (41, 110).

Wedge sled (210) of this example comprises a base including a baseplatform (212) and a central raised platform (214) extending upwardlyfrom base platform (212). In the example shown, base platform (212) hasa substantially flat bottom surface (216) defining a horizontal planeand configured to slide longitudinally along tray (74) while wedge sled(210) moves longitudinally through staple cartridge (37). Base platform(212) also has a laterally-opposed pair of substantially flat topsurfaces (218) parallel to bottom surface (216), and raised platform(214) similarly has a laterally-opposed pair of substantially flat topsurfaces (220) parallel to bottom surface (216). As best shown in FIG.13 , top surfaces (218, 220) are configured to confront and/or slidablycontact or otherwise engage respective bottom surfaces of correspondingwalls (71) of cartridge body (70) to thereby vertically support thecorresponding walls (71) while wedge sled (210) moves longitudinallythrough staple cartridge (37). In the present example, top surfaces(218) of base platform (212) are further configured to slidably contactor otherwise engage respective staple drivers (43) to thereby verticallysupport the respective staple drivers (43) while wedge sled (210) moveslongitudinally through staple cartridge (37), as described in greaterdetail below.

The base of the present version also includes a lower chamfer (222)inclined upwardly and distally from a distal end of bottom surface (216)to a distal end of base platform (212); a pair of distal upper chamfers(224) inclined downwardly and distally from respective distal ends oftop surfaces (218) of base platform (212) to the distal end of baseplatform (212); and a pair of proximal upper chamfers (226) inclineddownwardly and distally from respective distal ends of top surfaces(220) of raised platform (214) to respective top surfaces (218) of baseplatform. Chamfers (222, 224, 226) may also be referred to as “taperedsurfaces” or “bevels.” Lower chamfer (222) may extend across a width ofbase platform (212) and may have a length greater than a thickness ofbase platform (212) (e.g., between bottom surface (216) and either topsurface (218)). Likewise, distal upper chamfers (224) may each have alength greater than a thickness of base platform (212). Lower chamfer(222) may be configured to promote unimpeded longitudinal movement ofwedge sled (210) through staple cartridge (37) in the distal directionby reducing the likelihood of the distal end of base platform (212)catching, or otherwise being obstructed by, tray (74). For example,lower chamfer (222) may urge tray (74) (which may be constructed of aflexible material) slightly downwardly away from the bottom surfaces ofwalls (71) of cartridge body (70) as wedge sled (210) is driven distallythrough staple cartridge (37). Distal upper chamfers (224) may beconfigured to partially lift staple drivers (43) upwardly ontorespective top surfaces (218) of base platform (212) without driving thecorresponding staples (47) out through the corresponding stapleapertures (51) as wedge sled (210) is driven distally through staplecartridge (37). For example, distal upper chamfers (224) may beconfigured to cammingly engage staple drivers (43) to urge stapledrivers (43) onto respective top surfaces (218). In addition oralternatively, distal upper chamfers (224) may be configured to liftouter walls (71) of cartridge body (70) slightly upwardly ontorespective top surfaces (218) of base platform (212) as wedge sled (210)is driven distally through staple cartridge (37). For example, distalupper chamfers (224) may be configured to cammingly engage outer walls(71) to urge outer walls (71) onto respective top surfaces (218), asdescribed in greater detail below. In some versions, any one or more ofchamfers (222, 224, 226) may be omitted. For example, any one or more ofchamfers (222, 224, 226) may be replaced by one or more respectivefillets.

Wedge sled (210) further comprises a laterally-opposed pair of outersled rails (230) extending upwardly from base platform (212), andlaterally-opposed first and second inner sled rails (232, 233) extendingupwardly from both base platform (212) and raised platform (214). Sledrails (230, 232, 233) may also be referred to as “cam ramps” or “camwedges.” Sled rails (230, 232, 233) of the present version extendsubstantially straight and upright from the respective top surfaces(218, 220) of base platform (212) and raised platform (214), such thatsled rails (230, 232, 233) are perpendicularly oriented relative to thehorizontal plane and parallel to a vertical-longitudinal plane. In theexample shown, inner sled rails (232, 233) are laterally spaced apartfrom adjacent outer sled rails (230) to define top surfaces (218) ofbase platform (212). In this regard, top surfaces (218) of base platform(212) each extend at least partially along the lengths of sled rails(230, 232, 233), and top surfaces (220) of raised platform (214) eachextend at least partially along the length of the respective inner sledrail (232, 233). Moreover, top surfaces (218) of base platform (212) areeach at least partially positioned distally relative to distal ends ofsled rails (230, 232, 233). Outer sled rails (230) of the presentversion each have a first height relative to bottom surface (216) ofbase platform (212), while inner sled rails (232, 233) each have asecond height relative to bottom surface (216) of base platform (212)that is less than the first height. Also in the example shown, outer andinner sled rails (230, 232, 233) each terminate proximally at a samelongitudinal position (e.g., at a proximal end of base platform (212)),while outer sled rails (230) each terminate distally at a firstlongitudinal position, first inner sled rail (232) terminates distallyat a second longitudinal position that is distal relative to the firstlongitudinal position, and second inner sled rail (233) terminatesdistally at a third longitudinal position that is distal relative to thefirst and second longitudinal positions, such that outer sled rails(230) each have a first length, first inner sled rail (232) has a secondlength that is greater than the first length, and second inner sled rail(233) has a third length that is greater than the first and secondlengths. Thus, the distal ends of outer sled rails (230) are alignedwith each other in the longitudinal direction, and the distal ends offirst and second inner sled rails (232, 233) are offset from each otherand from the distal ends of outer sled rails (230) in the longitudinaldirection.

Each sled rail (230, 232, 233) is longitudinally aligned with arespective distal upper chamfer (224) of the base such that a respectivetop surface (218) of base platform (212) extends longitudinally betweeneach sled rail (230, 232, 233) and the respective distal upper chamfer(224). In some versions, the distal ends of sled rails (230, 232, 233)may each be spaced apart from the respective distal upper chamfers (224)by a distance equal to or greater than a length of the correspondingstaple drivers (43) such that the respective top surface (218) may becapable of supporting the corresponding staple drivers (43) between eachsled rail (230, 232, 233) and respective distal upper chamfer (224) inan upright manner.

As best shown in FIG. 13 , sled rails (230, 232, 233) are configured tobe received within corresponding longitudinally-extending slots (73) ofcartridge body (70), and to slidably contact or otherwise engagerespective side surfaces of corresponding walls (71) of cartridge body(70) to thereby horizontally stabilize walls (71) while wedge sled (210)moves longitudinally through staple cartridge (37). For example, outerand inner sled rails (230, 232, 233) may inhibit laterally inward and/orlaterally outward deflection (e.g., bending) of walls (71). In thisregard, sled rails (230, 232, 233) may each have a thickness equal to orslightly less than a width of the corresponding slot (73). In someversions, sled rails (230, 232, 233) may additionally or alternativelybe configured to slidably contact or otherwise engage respective upperslot surfaces of corresponding slots (73) of cartridge body (70) tothereby vertically support upper deck (72) while wedge sled (210) moveslongitudinally through staple cartridge (37).

Each sled rail (230, 232, 233) of wedge sled (210) presents one or morerespective inclined cam surfaces (240, 242, 244, 245, 246, 247) forfully lifting staple drivers (43) upwardly as wedge sled (210) is drivendistally through staple cartridge (37) to drive the correspondingstaples (47) out through the corresponding staple apertures (51). In theexample shown, each outer sled rail (230) includes a leading cam surface(240) oriented at a first angle relative to the horizontal plane definedby bottom surface (216) and a trailing cam surface (242) oriented at asecond angle relative to the horizontal plane, such that outer sledrails (230) have a same side elevational profile as each other.Likewise, first and second inner sled rails (232, 233) each include aleading cam surface (244, 245) oriented at the first angle relative tothe horizontal plane. In the example shown, first inner sled rail (232)includes a trailing cam surface (246) oriented at a third angle relativeto the horizontal plane and second inner sled rail (233) includes atrailing cam surface (247) oriented at a fourth angle relative to thehorizontal plane, such that inner sled rails (232, 233) have differentelevational profiles from each other and from that of outer sled rails(230). Thus, wedge sled (210) may be substantially asymmetric about thevertical-longitudinal plane, at least with respect to the configurationsof sled rails (230, 232, 233).

In the present version, the first angle is greater than the secondangle, which is greater than the third angle, which is greater than thefourth angle. Alternatively, any other suitable relative angles may beused.

Wedge sled (210) further comprises a central nose (250) extendingupwardly from both base platform (212) and raised platform (214) betweeninner sled rails (232, 233) and also extending distally from raisedplatform (214) to a distal tip (252). In the example shown, central nose(250) is laterally spaced apart from each inner sled rail (232, 233) todefine top surfaces (220) of raised platform (214). More particularly,central nose (250) is equally spaced apart from inner sled rails (232,233). Central nose (250) of the present version includes a lower portion(254) extending distally from raised platform (214) to distal tip (252),and an upper portion (256) extending upwardly from both raised platform(214) and lower portion (254). Upper portion (256) of the presentversion is substantially perpendicular to the horizontal plane. Asshown, upper portion (256) extends longitudinally from a proximal end ofraised platform (214) to distal tip (252), such that upper portion (256)is at least partially positioned distally relative to distal ends ofsled rails (230, 232, 233), and such that upper portion (256) extends atleast partially along the length of each sled rail (230, 232, 233).Distal tip (252) of the present version is positioned at a samelongitudinal position as the distal end of base platform (212).

In the example shown, lower portion (254) extends laterally outwardlyrelative to upper portion (256) on opposing sides of upper portion (256)to define a laterally-opposed pair of upwardly-facing ledge surfaces(262) extending longitudinally from respective top surfaces (220) ofraised platform (214) toward distal tip (252). More particularly, ledgesurfaces (262) are substantially flat, parallel to the horizontal plane,and positioned at a same height as top surfaces (220) of raised platform(214) relative to bottom surface (216), such that ledge surfaces (262)are seamlessly contiguous with respective top surfaces (220) of raisedplatform (214) to collectively define respective single continuoussurfaces. As shown, each ledge surface (262) is at least partiallypositioned distally relative to distal ends of sled rails (230, 232,233). Central nose (250) of the present version further includes alaterally-opposed pair of distal tapered surfaces (263) inclineddownwardly and distally from respective distal ends of ledge surfaces(262) toward distal tip (252). Tapered surfaces (263) may be configuredto lift inner walls (71) of cartridge body (70) slightly upwardly ontorespective ledge surfaces (262) of central nose (250) as wedge sled(210) is driven distally through staple cartridge (37). For example,tapered surfaces (263) may be configured to cammingly engage inner walls(71) to urge inner walls (71) onto respective ledge surfaces (262), asdescribed in greater detail below. In some versions, any one or more oftapered surfaces (263) may be omitted. For example, any one or more oftapered surfaces (263) may be replaced by one or more respectivefillets.

As best shown in FIG. 13 , central nose (250) is configured to be atleast partially received within vertical slot (49) of staple cartridge(37). In some versions, central nose (250) is configured to slidablycontact or otherwise engage inner walls (71) of cartridge body (70) tothereby vertically support and/or horizontally stabilize inner walls(71) while wedge sled (210) moves longitudinally through staplecartridge (37). In this regard, ledge surfaces (262) of the presentversion confront and slidably contact or otherwise engage respectivelower surfaces of inner walls (71) to thereby vertically support innerwalls (71) while wedge sled (210) moves longitudinally through staplecartridge (37). In addition, upper portion (256) of the present versioncontacts or otherwise engages laterally inward surfaces of inner walls(71) to thereby horizontally stabilize inner walls (71) while wedge sled(210) moves longitudinally through staple cartridge (37). For example,upper portion (256) may inhibit laterally inward deflection (e.g.,bending) of inner walls (71). In this regard, upper portion (256) mayhave a thickness equal to or slightly less than a width of vertical slot(49), while lower portion (254) may have a thickness greater than thewidth of vertical slot (49).

Since each top surface (218) of base platform (212) is at leastpartially positioned distally relative to distal ends of sled rails(230, 232, 233), top surfaces (218) may vertically support stapledrivers (43) and/or outer walls (71) of cartridge body (70) atlongitudinal positions that are distal relative to sled rails (230, 232,233) while wedge sled (210) moves longitudinally through staplecartridge (37). In this manner, base platform (212) may provide verticalsupport to staple drivers (43) and/or cartridge body (70) atlongitudinal positions corresponding to each staple aperture (51) alongthe length of cartridge body (70) in advance of (e.g., at leastimmediately prior to) the corresponding sled rail (230, 232, 233) fullylifting the corresponding staple driver (43) to drive the correspondingstaple (47) out through staple aperture (51). By providing verticalsupport to cartridge body (70) at such longitudinal positions in advanceof fully lifting staple drivers (43) to drive staples (47) out throughstaple apertures (51) at such longitudinal positions, base platform(212) may promote proper alignment of each staple aperture (51) with thecorresponding staple forming pocket (53) on the inner surface of anvil(18) in advance of deploying and forming each staple (47). For example,base platform (212) may promote vertical and/or angular alignment ofeach staple aperture (51) with the corresponding staple forming pocket(53) by assisting in maintaining upper deck (72) substantially parallelto the inner surface of anvil (18) having staple forming pockets (53).Likewise, by providing vertical support to staple drivers (43) at suchlongitudinal positions in advance of fully lifting staple drivers (43)to drive staples (47) out through staple apertures (51) at suchlongitudinal positions, base platform (212) may promote proper alignmentof each staple driver (43) with the corresponding staple forming pocket(53) on the inner surface of anvil (18) in advance of deploying andforming each staple (47). For example, base platform (212) may promotevertical and/or angular alignment of each staple driver (43) with thecorresponding staple forming pocket (53) by assisting in maintainingeach staple driver (43) substantially perpendicularly oriented relativeto the inner surface of anvil (18) having staple forming pockets (53),such as by inhibiting distal tipping of staple drivers (43) which mightotherwise occur when leading cam surfaces (240, 244, 245) of sled rails(230, 232, 233) cammingly engage staple drivers (43).

Similarly, since each ledge surface (262) of central nose (250) is atleast partially positioned distally relative to distal ends of sledrails (230, 232, 233), ledge surfaces (262) may vertically support innerwalls (71) of cartridge body (70) at longitudinal positions that aredistal relative to sled rails (230, 232, 233) while wedge sled (210)moves longitudinally through staple cartridge (37). Likewise, sinceupper portion (256) is at least partially positioned distally relativeto distal ends of sled rails (230, 232, 233), upper portion (256) mayhorizontally stabilize inner walls (71) of cartridge body (70) atlongitudinal positions that are distal relative to sled rails (230, 232,233) while wedge sled (210) moves longitudinally through staplecartridge (37). In this manner, central nose (250) may provide verticalsupport and/or horizontal stability to cartridge body (70) atlongitudinal positions corresponding to each staple aperture (51) alongthe length of cartridge body (70) in advance of (e.g., at leastimmediately prior to) the corresponding sled rail (230, 232, 233) fullylifting the corresponding staple driver (43) to drive the correspondingstaple (47) out through staple aperture (51). By providing verticalsupport and/or horizontal stability to cartridge body (70) at suchlongitudinal positions in advance of fully lifting staple drivers (43)to drive staples (47) out through staple apertures (51) at suchlongitudinal positions, central nose (250) may promote proper alignmentof each staple aperture (51) with the corresponding staple formingpocket (53) on the inner surface of anvil (18) in advance of deployingand forming each staple (47). For example, central nose (250) maypromote vertical and/or angular alignment of each staple aperture (51)with the corresponding staple forming pocket (53) by assisting inmaintaining upper deck (72) substantially parallel to the inner surfaceof anvil (18) having staple forming pockets (53), and/or by inhibitinglateral deflection of inner walls (71) which might otherwise causestaple apertures (51) to be angled (e.g., laterally inwardly orlaterally outwardly) relative to the corresponding staple forming pocket(53).

Moreover, since top surfaces (218, 220) of base platform (212) andraised platform (214) each extend at least partially along the length ofthe respective sled rail (230, 232, 233), top surfaces (218, 220) mayvertically support corresponding walls (71) of cartridge body (70) atthe same longitudinal positions at which sled rails (230, 232, 233) arelocated while wedge sled (210) moves longitudinally through staplecartridge (37). In this manner, base platform (212) and/or raisedplatform (214) may provide vertical support to cartridge body (70) atlongitudinal positions corresponding to each staple aperture (51) alongthe length of cartridge body (70) substantially contemporaneously with(e.g., during at least a portion of the duration of) the correspondingsled rail (230, 232, 233) fully lifting the corresponding staple driver(43) to drive the corresponding staple (47) out through staple aperture(51). By providing vertical support to cartridge body (70) at suchlongitudinal positions substantially contemporaneously with fullylifting staple drivers (43) to drive staples (47) out through stapleapertures (51) at such longitudinal positions, base platform (212)and/or raised platform (214) may promote proper alignment of each stapleaperture (51) with the corresponding staple forming pocket (53) on theinner surface of anvil (18) while deploying and forming each staple(47). For example, base platform (212) and/or raised platform (214) maypromote vertical and/or angular alignment of each staple aperture (51)with the corresponding staple forming pocket (53) by assisting inmaintaining upper deck (72) substantially parallel to the inner surfaceof anvil (18) having staple forming pockets (53). Since top surfaces(220) of raised platform (214) are seamlessly contiguous with respectiveledge surfaces (262), central nose (250) and raised platform (214) maycooperatively promote continuous proper alignment of each stapleaperture (51) with the corresponding staple forming pocket (53) on theinner surface of anvil (18) from at least immediately prior to deployingand forming each staple (47) to completion of deploying and forming eachstaple (47).

Additionally, since upper portion (256) of central nose (250) extends atleast partially along the length of each sled rail (230, 232, 233),upper portion (256) may horizontally stabilize inner walls (71) ofcartridge body (70) at the same longitudinal positions at which sledrails (230, 232, 233) are located while wedge sled (210) moveslongitudinally through staple cartridge (37). In this manner, centralnose (250) may provide horizontal stability to cartridge body (70) atlongitudinal positions corresponding to each staple aperture (51) alongthe length of cartridge body (70) substantially contemporaneously with(e.g., during at least a portion of the duration of) the correspondingsled rail (230, 232, 233) fully lifting the corresponding staple driver(43) to drive the corresponding staple (47) out through staple aperture(51). By providing horizontal stability to cartridge body (70) at suchlongitudinal positions substantially contemporaneously with fullylifting staple drivers (43) to drive staples (47) out through stapleapertures (51) at such longitudinal positions, central nose (250) maypromote proper alignment of each staple aperture (51) with thecorresponding staple forming pocket (53) on the inner surface of anvil(18) while deploying and forming each staple (47). For example, centralnose (250) may promote vertical and/or angular alignment of each stapleaperture (51) with the corresponding staple forming pocket (53) byinhibiting lateral deflection of inner walls (71) which might otherwisecause staple apertures (51) to be angled (e.g., laterally inwardly orlaterally outwardly) relative to the corresponding staple forming pocket(53). As discussed above, sled rails (230, 232, 233) may themselveshorizontally stabilize corresponding walls (71) of cartridge body (70)at their respective longitudinal positions, and thus may also promotevertical and/or angular alignment of each staple aperture (51) with thecorresponding staple forming pocket (53) by inhibiting lateraldeflection of inner walls (71) which might otherwise cause stapleapertures (51) to be angled (e.g., laterally inwardly or laterallyoutwardly) relative to the corresponding staple forming pocket (53).Therefore, central nose (250) and sled rails (230, 232, 233) maycooperatively provide horizontal stability to cartridge body (70) at therespective longitudinal positions of each sled rail (230, 232, 233)while wedge sled (210) moves longitudinally through staple cartridge(37). It should be understood that anvil (18) is intentionally omittedfrom the view in FIG. 13 .

Wedge sled (210) may be formed of any suitable material or combinationof materials, including but not limited to metallic materials such asstainless steel (e.g., hardened stainless steel) or titanium. In someversions, wedge sled (210) may be manufactured via a metal injectionmolding (MIM) process. It will be appreciated that such a MIM processmay provide wedge sled (210) with improved compression support and lesslateral deflection, and may enable wedge sled (210) to provide improvedrigidity to staple cartridge (37) during use (e.g., clamping and/orfiring). Such a MIM process may include molding wedge sled (210) as asingle unitary piece from a liquid MIM feedstock mix of metal powder andbinder, for example. The MIM process may further include subjectingwedge sled (210) to various types of conditioning, including but notlimited to cleaning, thermal debinding, and/or sintering.

In any event, after the MIM process is complete, all surfaces of wedgesled (210) may have an initial (e.g., raw MIM) surface finish, includingtop surfaces (218) of base platform (212), distal upper chamfers (224),and cam surfaces (240, 242, 244, 245, 246, 247) of sled rails (230, 232,233). Such an initial surface finish may be rough, abrasive, and/orgranular, and may generally be similar to the texture of pittedsandpaper. Thus, select surfaces of wedge sled (210) may be furtherconditioned to remove the initial surface finish from the selectsurfaces and provide the select surfaces with a final surface finishthat is relatively smoother (e.g., finer, more polished) than theinitial surface finish. For example, top surfaces (218) of base platform(212), distal upper chamfers (224), and cam surfaces (240, 242, 244,245, 246, 247) of sled rails (230, 232, 233) may be machined to removethe initial surface finish from top surfaces (218), distal upperchamfers (224), and cam surfaces (240, 242, 244, 245, 246, 247) andprovide top surfaces (218), distal upper chamfers (224), and camsurfaces (240, 242, 244, 245, 246, 247) with such a final surfacefinish. The final surface finish of top surfaces (218), distal upperchamfers (224), and cam surfaces (240, 242, 244, 245, 246, 247) maypromote reduced friction and smooth interaction between top surfaces(218), distal upper chamfers (224), and cam surfaces (240, 242, 244,245, 246, 247) and staple drivers (43) and thereby minimize wearing ofthe portions of staple drivers (43) contacted by top surfaces (218),distal upper chamfers (224), and cam surfaces (240, 242, 244, 245, 246,247).

While the select surfaces provided with the final surface finish havebeen described in the form of top surfaces (218) of base platform (212),distal upper chamfers (224), and cam surfaces (240, 242, 244, 245, 246,247) of sled rails (230, 232, 233), it will be appreciated that anyother surfaces of wedge sled (210) may additionally or alternatively beprovided with the final surface finish. For example, bottom surface(216) may be provided with the final surface finish to promote reducedfriction and smooth interaction between bottom surface (216) and tray(74).

In some versions, the remaining, non-select surfaces of wedge sled (210)may not be further conditioned such that the initial surface finish mayremain on the non-select surfaces during use (e.g., clamping and/orfiring). For example, top surfaces (220) of raised platform (214) and/orledge surfaces (262) of central nose (250) may retain the initialsurface finish. As another example, every surface of wedge sled (210)other than top surfaces (218) of base platform (212), distal upperchamfers (224), and cam surfaces (240, 242, 244, 245, 246, 247) of sledrails (230, 232, 233) may retain the initial surface finish. Thus, theselect surfaces of wedge sled (210) may have the final surface finishwhile the non-select surfaces of wedge sled (210) may have the initialsurface finish, such that wedge sled (210) may have at least twodistinct surface finishes.

The select and non-select surfaces may be determined based on theparticular components of staple cartridge (37) and/or firing beam (14)with which each individual surface of wedge sled (210) interacts. Inthis regard, the final surface finish may be more desirable for surfacesof wedge sled (210) which interact with certain predetermined componentsof staple cartridge (37) and/or firing beam (14) than others. Forexample, top surfaces (218) of base platform (212), distal upperchamfers (224), and cam surfaces (240, 242, 244, 245, 246, 247) of sledrails (230, 232, 233) may be selected to receive the final surfacefinish based on their interaction with staple drivers (43), while theremaining surfaces of sled rails (230, 232, 233), top surfaces (220) ofraised platform (214), and/or ledge surfaces (262) of central nose (250)may not be selected to receive the final surface finish based on theirinteraction with cartridge body (70). As another example, bottom surface(216) may be selected to receive the final surface finish based on itsinteraction with tray (74), while a proximal end surface of wedge sled(210) may not be selected to receive the final surface finish based onits interaction with pusher block (80).

Referring now to FIGS. 14A-14D, during firing, wedge sled (210) isdriven distally from a proximal position shown in FIG. 14A into upwardcamming contact with staple drivers (43) that in turn drive staples (47)out through staple apertures (51) and into forming contact with stapleforming pockets (53) on the inner surface of anvil (18). Moreparticularly, distal upper chamfer (224) of base platform (212)cammingly engages a respective staple driver (43) during distaltranslation of wedge sled (210) to lift the respective staple driver(43) above tray (74), as shown in FIG. 14B. For example, distal upperchamfer (224) may lift the respective staple driver (43) to a firstheight onto the respective top surface (218) of base platform (212)without ejecting the corresponding staple (47) through the correspondingstaple aperture (51). Thus, distal upper chamfer (224) may be consideredto “partially” lift the respective staple driver (43). Top surface (218)then vertically supports the respective staple driver (43) duringcontinued distal translation of wedge sled (210), as shown in FIG. 14C.For example, top surface (218) may temporarily maintain the respectivestaple driver (43) at the first height. Cam surfaces (240, 242, 244,245, 246, 247) of the respective sled rail (230, 232) then camminglyengage the respective staple driver (43) during further distaltranslation of wedge sled (210) to lift the respective staple driver(43) above the respective top surface (218) of base platform (212), asshown in FIG. 14D. For example, cam surfaces (240, 242, 244, 245, 246,247) may lift the respective staple driver (43) to a second heightgreater than the first height to eject the corresponding staple (47)through the corresponding staple aperture (51) and into forming contactwith the corresponding staple forming pocket (53). Thus, cam surfaces(240, 242, 244, 245, 246, 247) may be considered to “fully” lift therespective staple driver (43). It should be understood that stapleforming pockets (53) are intentionally omitted from the view in FIGS.14A-14D.

IV. EXEMPLARY SLEDS HAVING CARTRIDGE BIASING FEATURES

In some instances, it may be desirable to provide a wedge sled that isconfigured to provide further horizontal stability to staple cartridge(37) by biasing the walls of cartridge body (70) adjacent to the wedgesled laterally inwardly. FIGS. 15-19 show exemplary wedge sleds (310,410, 510, 610, 710) which each provide such functionalities. Wedge sleds(310, 410, 510, 610, 710) are each similar to wedge sled (110) and/orwedge sled (210) described above except as otherwise described below.For example, wedge sleds (310, 410, 510, 610, 710) each occupy the sameamount of space longitudinally within staple cartridge (37) as wedgesleds (41, 110, 210), making wedge sleds (310, 410, 510, 610, 710)substantially interchangeable with wedge sleds (41, 110, 210).

A. Exemplary Sled Having Toed-In Inner and Outer Sled Rails andUndercuts

FIG. 15 depicts an exemplary wedge sled (310) comprising a baseincluding a base platform (312) and a central raised platform (314)extending upwardly from base platform (312). In the example shown, baseplatform (312) has a substantially flat bottom surface (316) defining ahorizontal plane and configured to slide longitudinally along tray (74)while wedge sled (310) moves longitudinally through staple cartridge(37). Base platform (312) also has a laterally-opposed pair ofsubstantially flat top surfaces (318) parallel to bottom surface (316),and raised platform (314) similarly has a laterally-opposed pair ofsubstantially flat top surfaces (320) parallel to bottom surface (316).As shown, top surfaces (318, 320) are configured to confront and/orslidably contact or otherwise engage respective bottom surfaces ofcorresponding walls (71) of cartridge body (70) to thereby verticallysupport the corresponding walls (71) while wedge sled (310) moveslongitudinally through staple cartridge (37).

Wedge sled (310) further comprises a laterally-opposed pair of outersled rails (330) extending upwardly from base platform (312), and alaterally-opposed pair of inner sled rails (332) extending upwardly fromboth base platform (312) and raised platform (314). Sled rails (330,332) may also be referred to as “cam ramps” or “cam wedges.” Sled rails(330, 332) of the present version are each tilted or bent laterallyinwardly from the respective top surfaces (318, 320) of base platform(312) and raised platform (314), such that sled rails (330, 332) areobliquely oriented relative to the horizontal plane and relative to avertical-longitudinal plane. More particularly, each sled rail (330,332) is bent laterally inwardly at a same oblique angle (α) relative tothe vertical-longitudinal plane (or to any plane parallel thereto), suchthat sled rails (330, 332) on each side of the vertical-longitudinalplane are parallel to each other and such that wedge sled (310) issubstantially symmetric about the vertical-longitudinal plane, at leastwith respect to the configurations of sled rails (330, 332). In someversions, oblique angle (α) may be approximately 7.5°. Alternatively,any other suitable angle may be used. In the example shown, wedge sled(310) includes a laterally-opposed pair of recesses (334) extendingdownwardly from top surfaces (320) of raised platform (314) adjacent tothe corresponding inner sled rails (332) to assist with facilitating thelaterally-inwardly bent configurations of inner sled rails (332).Recesses (334) may also be referred to as “undercuts.” In some versions,recesses (334) may each extend at least partially along the length ofthe respective inner sled rail (332).

As shown, sled rails (330, 332) are configured to be received withincorresponding longitudinally-extending slots (73) of cartridge body(70), and to slidably contact or otherwise engage respective sidesurfaces of corresponding walls (71) of cartridge body (70) to therebyhorizontally stabilize walls (71) while wedge sled (310) moveslongitudinally through staple cartridge (37). For example, outer andinner sled rails (330, 332) may inhibit laterally inward and/orlaterally outward deflection (e.g., bending) of walls (71). In thisregard, the laterally-inwardly bent configurations of sled rails (330,332) of the present version may be particularly suitable for inhibitinglaterally outward deflection of walls (71). For example, sled rails(330, 332) of the present version may bias the corresponding walls (71)toward a substantially vertical orientation by counteracting anylaterally-outwardly directed forces that might be applied to walls (71)during use (e.g., clamping and/or firing). In this regard, oblique angle(α) may be selected to achieve a desired amount of laterally-inwardlydirected force applied by each sled rail (330, 332) to the correspondingwall (71) sufficient to overcome such laterally-outwardly directedforces while causing limited or no laterally-inward bending of thecorresponding wall (71). Likewise, sled rails (330, 332) may each beattached to base platform (312) and raised platform (314), respectively,with a predetermined amount of flexibility to minimize laterally-inwardbending of the corresponding wall (71) by allowing sled rails (330, 332)to be resiliently urged laterally outwardly upon application of athreshold force thereto. Thus, sled rails (330, 332) may be consideredto be resiliently biased laterally inwardly. In some versions, sledrails (330, 332) may additionally or alternatively be configured toslidably contact or otherwise engage respective upper slot surfaces ofcorresponding slots (73) of cartridge body (70) to thereby verticallysupport upper deck (72) while wedge sled (310) moves longitudinallythrough staple cartridge (37).

Wedge sled (310) further comprises a central nose (350) extendingupwardly from raised platform (314) between inner sled rails (332). Inthe example shown, central nose (350) is laterally spaced apart fromeach recess (334) to define top surfaces (320) of raised platform (314).

As shown, central nose (350) is configured to be at least partiallyreceived within vertical slot (49) of staple cartridge (37). In someversions, central nose (350) is configured to slidably contact orotherwise engage inner walls (71) of cartridge body (70) to therebyvertically support and/or horizontally stabilize inner walls (71) whilewedge sled (310) moves longitudinally through staple cartridge (37), asdescribed above with respect to central noses (150, 250). For example,central nose (350) may inhibit laterally inward deflection (e.g.,bending) of inner walls (71) which might otherwise be caused by thelaterally-inwardly directed forces applied to inner walls (71) by thecorresponding inner sled rails (332). Likewise, inner sled rails (332)may inhibit laterally inward deflection (e.g., bending) of outer walls(71) which might otherwise be caused by the laterally-inwardly directedforces applied to outer walls (71) by the corresponding outer sled rails(330). In some versions, some laterally inward deflection of innerand/or outer walls (71) may be permitted which does not deform theoverall exterior shape of staple cartridge (37) and, more particularly,which does not cause misalignment of staple apertures (51) relative tothe corresponding staple forming pockets (53). Thus, central nose (350)and sled rails (330, 332) may cooperatively provide improved horizontalstability to cartridge body (70) at the respective longitudinalpositions of each sled rail (330, 332) while wedge sled (310) moveslongitudinally through staple cartridge (37). It should be understoodthat anvil (18) is intentionally omitted from the view in FIG. 15 .

B. Exemplary Sled Having Toed-In Inner and Outer Sled Rails

FIG. 16 depicts an exemplary wedge sled (410) comprising a baseincluding a base platform (412) and a central raised platform (414)extending upwardly from base platform (412). In the example shown, baseplatform (412) has a substantially flat bottom surface (416) defining ahorizontal plane and configured to slide longitudinally along tray (74)while wedge sled (410) moves longitudinally through staple cartridge(37). Base platform (412) also has a laterally-opposed pair ofsubstantially flat top surfaces (418) parallel to bottom surface (416),and raised platform (414) similarly has a laterally-opposed pair ofsubstantially flat top surfaces (420) parallel to bottom surface (416).As shown, top surfaces (418, 420) are configured to confront and/orslidably contact or otherwise engage respective bottom surfaces ofcorresponding walls (71) of cartridge body (70) to thereby verticallysupport the corresponding walls (71) while wedge sled (410) moveslongitudinally through staple cartridge (37).

Wedge sled (410) further comprises a laterally-opposed pair of outersled rails (430) extending upwardly from base platform (412), and alaterally-opposed pair of inner sled rails (432) extending upwardly fromboth base platform (412) and raised platform (414). Sled rails (430,432) may also be referred to as “cam ramps” or “cam wedges.” Sled rails(430, 432) of the present version are each tilted or bent laterallyinwardly from the respective top surfaces (418, 420) of base platform(412) and raised platform (414), such that sled rails (430, 432) areobliquely oriented relative to the horizontal plane and relative to avertical-longitudinal plane. More particularly, each sled rail (430,432) is bent laterally inwardly at a same oblique angle (α) relative tothe vertical-longitudinal plane (or to any plane parallel thereto), suchthat sled rails (430, 432) on each side of the vertical-longitudinalplane are parallel to each other and such that wedge sled (410) issubstantially symmetric about the vertical-longitudinal plane, at leastwith respect to the configurations of sled rails (430, 432). In someversions, oblique angle (α) may be approximately 7.5°. Alternatively,any other suitable angle may be used.

As shown, sled rails (430, 432) are configured to be received withincorresponding longitudinally-extending slots (73) of cartridge body(70), and to slidably contact or otherwise engage respective sidesurfaces of corresponding walls (71) of cartridge body (70) to therebyhorizontally stabilize walls (71) while wedge sled (410) moveslongitudinally through staple cartridge (37). For example, outer andinner sled rails (430, 432) may inhibit laterally inward and/orlaterally outward deflection (e.g., bending) of walls (71). In thisregard, the laterally-inwardly bent configurations of sled rails (430,432) of the present version may be particularly suitable for inhibitinglaterally outward deflection of walls (71). For example, sled rails(430, 432) of the present version may bias the corresponding walls (71)toward a substantially vertical orientation by counteracting anylaterally-outwardly directed forces that might be applied to walls (71)during use (e.g., clamping and/or firing). In this regard, oblique angle(α) may be selected to achieve a desired amount of laterally-inwardlydirected force applied by each sled rail (430, 432) to the correspondingwall (71) sufficient to overcome such laterally-outwardly directedforces while causing limited or no laterally-inward bending of thecorresponding wall (71). Likewise, sled rails (430, 432) may each beattached to base platform (412) and raised platform (414), respectively,with a predetermined amount of flexibility to minimize laterally-inwardbending of the corresponding wall (71) by allowing sled rails (430, 432)to be resiliently urged laterally outwardly upon application of athreshold force thereto. Thus, sled rails (430, 432) may be consideredto be resiliently biased laterally inwardly. In some versions, sledrails (430, 432) may additionally or alternatively be configured toslidably contact or otherwise engage respective upper slot surfaces ofcorresponding slots (73) of cartridge body (70) to thereby verticallysupport upper deck (72) while wedge sled (410) moves longitudinallythrough staple cartridge (37).

Wedge sled (410) further comprises a central nose (450) extendingupwardly from raised platform (414) between inner sled rails (432). Inthe example shown, central nose (450) is laterally spaced apart fromeach inner sled rail (432) to define top surfaces (420) of raisedplatform (414). More particularly, central nose (450) is equally spacedapart from inner sled rails (432).

As shown, central nose (450) is configured to be at least partiallyreceived within vertical slot (49) of staple cartridge (37). In someversions, central nose (450) is configured to slidably contact orotherwise engage inner walls (71) of cartridge body (70) to therebyvertically support and/or horizontally stabilize inner walls (71) whilewedge sled (410) moves longitudinally through staple cartridge (37), asdescribed above with respect to central noses (150, 250). For example,central nose (450) may inhibit laterally inward deflection (e.g.,bending) of inner walls (71) which might otherwise be caused by thelaterally-inwardly directed forces applied to inner walls (71) by thecorresponding inner sled rails (432). Likewise, inner sled rails (432)may inhibit laterally inward deflection (e.g., bending) of outer walls(71) which might otherwise be caused by the laterally-inwardly directedforces applied to outer walls (71) by the corresponding outer sled rails(430). In some versions, some laterally inward deflection of innerand/or outer walls (71) may be permitted which does not deform theoverall exterior shape of staple cartridge (37) and, more particularly,which does not cause misalignment of staple apertures (51) relative tothe corresponding staple forming pockets (53). Thus, central nose (450)and sled rails (430, 432) may cooperatively provide improved horizontalstability to cartridge body (70) at the respective longitudinalpositions of each sled rail (430, 432) while wedge sled (410) moveslongitudinally through staple cartridge (37). It should be understoodthat anvil (18) is intentionally omitted from the view in FIG. 16 .

C. Exemplary Sled Having Toed-In Inner Sled Rails

FIG. 17 depicts an exemplary wedge sled (510) comprising a baseincluding a base platform (512) and a central raised platform (514)extending upwardly from base platform (512). In the example shown, baseplatform (512) has a substantially flat bottom surface (516) defining ahorizontal plane and configured to slide longitudinally along tray (74)while wedge sled (510) moves longitudinally through staple cartridge(37). Base platform (512) also has a laterally-opposed pair ofsubstantially flat top surfaces (518) parallel to bottom surface (516),and raised platform (514) similarly has a laterally-opposed pair ofsubstantially flat top surfaces (520) parallel to bottom surface (516).As shown, top surfaces (518, 520) are configured to confront and/orslidably contact or otherwise engage respective bottom surfaces ofcorresponding walls (71) of cartridge body (70) to thereby verticallysupport the corresponding walls (71) while wedge sled (510) moveslongitudinally through staple cartridge (37).

Wedge sled (510) further comprises a laterally-opposed pair of outersled rails (530) extending upwardly from base platform (512), and alaterally-opposed pair of inner sled rails (532) extending upwardly fromboth base platform (512) and raised platform (514). Sled rails (530,532) may also be referred to as “cam ramps” or “cam wedges.” Outer sledrails (530) of the present version extend substantially straight andupright from the respective top surfaces (518) of base platform (512),such that outer sled rails (530) are perpendicularly oriented relativeto the horizontal plane and parallel to a vertical-longitudinal plane.Inner sled rails (532) of the present version are each tilted or bentlaterally inwardly from the respective top surfaces (520) of raisedplatform (514), such that inner sled rails (532) are obliquely orientedrelative to the horizontal plane and relative to a vertical-longitudinalplane. More particularly, each inner sled rail (532) is bent laterallyinwardly at an oblique angle (α) relative to the vertical-longitudinalplane (or to any plane parallel thereto), such that inner sled rails(532) are each obliquely oriented relative to the adjacent outer sledrail (530) and such that wedge sled (510) is substantially symmetricabout the vertical-longitudinal plane, at least with respect to theconfigurations of sled rails (530, 532). In some versions, oblique angle(α) may be approximately 7.5°. Alternatively, any other suitable anglemay be used.

As shown, sled rails (530, 532) are configured to be received withincorresponding longitudinally-extending slots (73) of cartridge body(70), and to slidably contact or otherwise engage respective sidesurfaces of corresponding walls (71) of cartridge body (70) to therebyhorizontally stabilize walls (71) while wedge sled (510) moveslongitudinally through staple cartridge (37). For example, outer andinner sled rails (530, 532) may inhibit laterally inward and/orlaterally outward deflection (e.g., bending) of walls (71). In thisregard, the laterally-inwardly bent configurations of inner sled rails(532) of the present version may be particularly suitable for inhibitinglaterally outward deflection of inner walls (71). For example, innersled rails (532) of the present version may bias the corresponding innerwalls (71) toward a substantially vertical orientation by counteractingany laterally-outwardly directed forces that might be applied to innerwalls (71) during use (e.g., clamping and/or firing). In this regard,oblique angle (α) may be selected to achieve a desired amount oflaterally-inwardly directed force applied by each inner sled rail (532)to the corresponding inner wall (71) sufficient to overcome suchlaterally-outwardly directed forces while causing limited or nolaterally-inward bending of the corresponding wall (71). Likewise, innersled rails (532) may each be attached to raised platform (514) with apredetermined amount of flexibility to minimize laterally-inward bendingof the corresponding wall (71) by allowing inner sled rails (532) to beresiliently urged laterally outwardly upon application of a thresholdforce thereto. Thus, inner sled rails (532) may be considered to beresiliently biased laterally inwardly. In some versions, sled rails(530, 532) may additionally or alternatively be configured to slidablycontact or otherwise engage respective upper slot surfaces ofcorresponding slots (73) of cartridge body (70) to thereby verticallysupport upper deck (72) while wedge sled (510) moves longitudinallythrough staple cartridge (37).

Wedge sled (510) further comprises a central nose (550) extendingupwardly from raised platform (514) between inner sled rails (532). Inthe example shown, central nose (550) is laterally spaced apart fromeach inner sled rail (532) to define top surfaces (520) of raisedplatform (514). More particularly, central nose (550) is equally spacedapart from inner sled rails (532).

As shown, central nose (550) is configured to be at least partiallyreceived within vertical slot (49) of staple cartridge (37). In someversions, central nose (550) is configured to slidably contact orotherwise engage inner walls (71) of cartridge body (70) to therebyvertically support and/or horizontally stabilize inner walls (71) whilewedge sled (510) moves longitudinally through staple cartridge (37), asdescribed above with respect to central noses (150, 250). For example,central nose (550) may inhibit laterally inward deflection (e.g.,bending) of inner walls (71) which might otherwise be caused by thelaterally-inwardly directed forces applied to inner walls (71) by thecorresponding inner sled rails (532). Likewise, inner sled rails (532)may inhibit laterally inward deflection (e.g., bending) of outer walls(71) which might otherwise be caused by the laterally-inwardly directedforces applied to outer walls (71) by the corresponding outer sled rails(530). In some versions, some laterally inward deflection of innerand/or outer walls (71) may be permitted which does not deform theoverall exterior shape of staple cartridge (37) and, more particularly,which does not cause misalignment of staple apertures (51) relative tothe corresponding staple forming pockets (53). Thus, central nose (550)and sled rails (530, 532) may cooperatively provide improved horizontalstability to cartridge body (70) at the respective longitudinalpositions of each sled rail (530, 532) while wedge sled (510) moveslongitudinally through staple cartridge (37). It should be understoodthat anvil (18) is intentionally omitted from the view in FIG. 17 .

D. Exemplary Sled Having V-Shaped Base

FIG. 18 depicts an exemplary wedge sled (610) comprising a baseincluding a base platform (612) and a central raised platform (614)extending upwardly from base platform (612). In the example shown, baseplatform (612) and raised platform (614) are each bifurcated by alongitudinally-extending inverted V-shaped slot (615) such thatlaterally-opposing halves of wedge sled (610) may each be tilted or bentlaterally inwardly toward each other. In this regard, base platform(612) has a laterally-opposed pair of substantially flat bottom surfaces(616) obliquely oriented relative to a horizontal plane (e.g.,collectively defined by lowermost, laterally-inner edges of bottomsurfaces (616)). More particularly, each bottom surface (616) is bentlaterally inwardly at a same oblique angle (θ) relative to thehorizontal plane, such that base platform (612) has a generally V-shapedcross section and such that wedge sled (610) is substantially symmetricabout the vertical-longitudinal plane, at least with respect to theconfigurations of bottom surfaces (616). Base platform (612) also has alaterally-opposed pair of substantially flat top surfaces (618) parallelto respective bottom surfaces (616), and raised platform (614) similarlyhas a laterally-opposed pair of substantially flat top surfaces (620)parallel to respective bottom surfaces (616). Top surfaces (618, 620)are configured to confront and/or slidably contact or otherwise engagerespective bottom surfaces of corresponding walls (71) of cartridge body(70) to thereby vertically support the corresponding walls (71) whilewedge sled (610) moves longitudinally through staple cartridge (37).

Wedge sled (610) further comprises a laterally-opposed pair of outersled rails (630) extending upwardly from base platform (612), and alaterally-opposed pair of inner sled rails (632) extending upwardly fromboth base platform (612) and raised platform (614). Sled rails (630,632) may also be referred to as “cam ramps” or “cam wedges.” Sled rails(630, 632) of the present version extend substantially straight andupright from the respective top surfaces (618, 620) of base platform(612) and raised platform (614), such that sled rails (630, 632) areobliquely oriented relative to the horizontal plane and relative to avertical-longitudinal plane via the oblique orientations of bottomsurfaces (616) relative to the horizontal plane. More particularly, dueto the laterally-inwardly bent configuration of base platform (612),each sled rail (630, 632) is bent laterally inwardly at a same obliqueangle (α) relative to the vertical-longitudinal plane (or to any planeparallel thereto), such that sled rails (630, 632) on each side of thevertical-longitudinal plane are parallel to each other and such thatwedge sled (610) is substantially symmetric about thevertical-longitudinal plane, at least with respect to the configurationsof sled rails (630, 632). In some versions, oblique angle (α) may beapproximately 7.5°. Alternatively, any other suitable angle may be used.

Sled rails (630, 632) are configured to be received within correspondinglongitudinally-extending slots (73) of cartridge body (70), and toslidably contact or otherwise engage respective side surfaces ofcorresponding walls (71) of cartridge body (70) to thereby horizontallystabilize walls (71) while wedge sled (610) moves longitudinally throughstaple cartridge (37). For example, outer and inner sled rails (630,632) may inhibit laterally inward and/or laterally outward deflection(e.g., bending) of walls (71). In this regard, the laterally-inwardlybent configurations of sled rails (630, 632) of the present version maybe particularly suitable for inhibiting laterally outward deflection ofwalls (71). For example, sled rails (630, 632) of the present versionmay bias the corresponding walls (71) toward a substantially verticalorientation by counteracting any laterally-outwardly directed forcesthat might be applied to walls (71) during use (e.g., clamping and/orfiring). In this regard, oblique angle (θ) and/or oblique angle (α) maybe selected to achieve a desired amount of laterally-inwardly directedforce applied by each sled rail (630, 632) to the corresponding wall(71) sufficient to overcome such laterally-outwardly directed forceswhile causing limited or no laterally-inward bending of thecorresponding wall (71). Slot (615) may provide the laterally-opposinghalves of wedge sled (610) with a predetermined amount of flexibility tominimize laterally-inward bending of the corresponding wall (71) byallowing sled rails (630, 632) to be resiliently urged laterallyoutwardly upon application of a threshold force thereto. Thus, sledrails (630, 632) may be considered to be resiliently biased laterallyinwardly. In some versions, sled rails (630, 632) may additionally oralternatively be configured to slidably contact or otherwise engagerespective upper slot surfaces of corresponding slots (73) of cartridgebody (70) to thereby vertically support upper deck (72) while wedge sled(610) moves longitudinally through staple cartridge (37).

Wedge sled (610) further comprises a central nose (650) extendingupwardly from raised platform (614) between inner sled rails (632). Inthe example shown, central nose (650) is laterally spaced apart fromeach recess (634) to define top surfaces (620) of raised platform (614).

Central nose (650) is configured to be at least partially receivedwithin vertical slot (49) of staple cartridge (37). In some versions,central nose (650) is configured to slidably contact or otherwise engageinner walls (71) of cartridge body (70) to thereby vertically supportand/or horizontally stabilize inner walls (71) while wedge sled (610)moves longitudinally through staple cartridge (37), as described abovewith respect to central noses (150, 250). For example, central nose(650) may inhibit laterally inward deflection (e.g., bending) of innerwalls (71) which might otherwise be caused by the laterally-inwardlydirected forces applied to inner walls (71) by the corresponding innersled rails (632). Likewise, inner sled rails (632) may inhibit laterallyinward deflection (e.g., bending) of outer walls (71) which mightotherwise be caused by the laterally-inwardly directed forces applied toouter walls (71) by the corresponding outer sled rails (630). In someversions, some laterally inward deflection of inner and/or outer walls(71) may be permitted which does not deform the overall exterior shapeof staple cartridge (37) and, more particularly, which does not causemisalignment of staple apertures (51) relative to the correspondingstaple forming pockets (53). Thus, central nose (650) and sled rails(630, 632) may cooperatively provide improved horizontal stability tocartridge body (70) at the respective longitudinal positions of eachsled rail (630, 632) while wedge sled (610) moves longitudinally throughstaple cartridge (37).

E. Exemplary Sled Having Bifurcated Nose

FIG. 19 depicts an exemplary wedge sled (710) comprising a baseincluding a base platform (712) and a central raised platform (714)extending upwardly from base platform (712). In the example shown, baseplatform (712) has a substantially flat bottom surface (716) defining ahorizontal plane and configured to slide longitudinally along tray (74)while wedge sled (710) moves longitudinally through staple cartridge(37). Base platform (712) also has a laterally-opposed pair ofsubstantially flat top surfaces (718) parallel to bottom surface (716),and raised platform (714) similarly has a laterally-opposed pair ofsubstantially flat top surfaces (720) parallel to bottom surface (716).Top surfaces (718, 720) are configured to confront and/or slidablycontact or otherwise engage respective bottom surfaces of correspondingwalls (71) of cartridge body (70) to thereby vertically support thecorresponding walls (71) while wedge sled (710) moves longitudinallythrough staple cartridge (37).

Wedge sled (710) further comprises a laterally-opposed pair of outersled rails (730) extending upwardly from base platform (712), and alaterally-opposed pair of inner sled rails (732) extending upwardly fromboth base platform (712) and raised platform (714). Sled rails (730,732) may also be referred to as “cam ramps” or “cam wedges.” Sled rails(730, 732) of the present version are each tilted or bent laterallyinwardly from the respective top surfaces (718, 720) of base platform(712) and raised platform (714), such that sled rails (730, 732) areobliquely oriented relative to the horizontal plane and relative to avertical-longitudinal plane. More particularly, each sled rail (730,732) is bent laterally inwardly at a same oblique angle (α) relative tothe vertical-longitudinal plane (or to any plane parallel thereto), suchthat sled rails (730, 732) on each side of the vertical-longitudinalplane are parallel to each other and such that wedge sled (710) issubstantially symmetric about the vertical-longitudinal plane, at leastwith respect to the configurations of sled rails (730, 732). In someversions, oblique angle (α) may be approximately 7.5°. Alternatively,any other suitable angle may be used. In the example shown, wedge sled(710) includes a laterally-opposed pair of recesses (734) extendingdownwardly from top surfaces (720) of raised platform (714) adjacent tothe corresponding inner sled rails (732) to assist with facilitating thelaterally-inwardly bent configurations of inner sled rails (732).Recesses (734) may also be referred to as “undercuts.” In some versions,recesses (734) may each extend at least partially along the length ofthe respective inner sled rail (732).

Sled rails (730, 732) are configured to be received within correspondinglongitudinally-extending slots (73) of cartridge body (70), and toslidably contact or otherwise engage respective side surfaces ofcorresponding walls (71) of cartridge body (70) to thereby horizontallystabilize walls (71) while wedge sled (710) moves longitudinally throughstaple cartridge (37). For example, outer and inner sled rails (730,732) may inhibit laterally inward and/or laterally outward deflection(e.g., bending) of walls (71). In this regard, the laterally-inwardlybent configurations of sled rails (730, 732) of the present version maybe particularly suitable for inhibiting laterally outward deflection ofwalls (71). For example, sled rails (730, 732) of the present versionmay bias the corresponding walls (71) toward a substantially verticalorientation by counteracting any laterally-outwardly directed forcesthat might be applied to walls (71) during use (e.g., clamping and/orfiring). In this regard, oblique angle (α) may be selected to achieve adesired amount of laterally-inwardly directed force applied by each sledrail (730, 732) to the corresponding wall (71) sufficient to overcomesuch laterally-outwardly directed forces while causing limited or nolaterally-inward bending of the corresponding wall (71). Likewise, sledrails (730, 732) may each be attached to base platform (712) and raisedplatform (714), respectively, with a predetermined amount of flexibilityto minimize laterally-inward bending of the corresponding wall (71) byallowing sled rails (730, 732) to be resiliently urged laterallyoutwardly upon application of a threshold force thereto. Thus, sledrails (730, 732) may be considered to be resiliently biased laterallyinwardly. In some versions, sled rails (730, 732) may additionally oralternatively be configured to slidably contact or otherwise engagerespective upper slot surfaces of corresponding slots (73) of cartridgebody (70) to thereby vertically support upper deck (72) while wedge sled(710) moves longitudinally through staple cartridge (37).

Wedge sled (710) further comprises a central nose (750) extendingupwardly from raised platform (714) between inner sled rails (732). Inthe example shown, central nose (750) is laterally spaced apart fromeach recess (734) to define top surfaces (720) of raised platform (714).In the present version, central nose (750) is bifurcated by alongitudinally-extending U-shaped slot (751) to facilitatelaterally-inward deflection (e.g., bending) of central nose (750).

Central nose (750) is configured to be at least partially receivedwithin vertical slot (49) of staple cartridge (37). In some versions,central nose (750) is configured to slidably contact or otherwise engageinner walls (71) of cartridge body (70) to thereby vertically supportand/or horizontally stabilize inner walls (71) while wedge sled (710)moves longitudinally through staple cartridge (37), as described abovewith respect to central noses (150, 250). For example, central nose(750) may inhibit laterally inward deflection (e.g., bending) of innerwalls (71) which might otherwise be caused by the laterally-inwardlydirected forces applied to inner walls (71) by the corresponding innersled rails (732). Likewise, inner sled rails (732) may inhibit laterallyinward deflection (e.g., bending) of outer walls (71) which mightotherwise be caused by the laterally-inwardly directed forces applied toouter walls (71) by the corresponding outer sled rails (730). In someversions, some laterally inward deflection of inner and/or outer walls(71) may be permitted which does not deform the overall exterior shapeof staple cartridge (37) and, more particularly, which does not causemisalignment of staple apertures (51) relative to the correspondingstaple forming pockets (53). In this regard, central nose (750) may bendlaterally-inwardly to accommodate such permitted laterally inwarddeflection of inner walls (71). Thus, central nose (750) and sled rails(730, 732) may cooperatively provide improved horizontal stability tocartridge body (70) at the respective longitudinal positions of eachsled rail (730, 732) while wedge sled (710) moves longitudinally throughstaple cartridge (37).

While wedge sleds (110, 210, 310, 410, 510, 610, 710) of the presentversions are shown and described herein in connection with staplecartridges configured for use with laparoscopic surgical staplers, suchas staple cartridge (37), it will be appreciated that wedge sleds (110,210, 310, 410, 510, 610, 710) of other versions may be adapted for usewith staple cartridges configured for use with non-laparoscopic surgicalstaplers in open surgical procedures. Examples of such non-laparoscopicsurgical staplers are disclosed in U.S. Pat. Pub. No. 2020/0046350,entitled “Firing System for Linear Surgical Stapler,” published on Feb.13, 2020; U.S. Pat. Pub. No. 2020/0046351, entitled “DecouplingMechanism for Linear Surgical Stapler,” published on Feb. 13, 2020; U.S.Pat. Pub. No. 2020/0046353, entitled “Clamping Assembly for LinearSurgical Stapler,” published on Feb. 13, 2020; and U.S. application Ser.No. 16/537,005, entitled “Linear Surgical Stapler,” filed Aug. 9, 2019.The disclosures of these references are incorporated by referenceherein.

V. EXEMPLARY BIASING FEATURES INTEGRATED INTO CARTRIDGE

In some instances, it may be desirable to provide a staple cartridgethat possesses improved horizontal stability as compared to staplecartridge (37) by biasing the walls of the cartridge body adjacent towedge sled (41) laterally inwardly. FIG. 20 shows an exemplary staplecartridge (868) which provides such functionality. Staple cartridge(868) is similar to staple cartridge (37) described above except asotherwise described below. For example, staple cartridge (37) isconfigured to be removably installed into a channel (39) of lower jaw(16).

As shown, staple cartridge (868) of this example includes a cartridgebody (870) having a plurality of walls (871), and which presents anupper deck (872). Cartridge body (870) further has a plurality oflongitudinally-extending slots (873) positioned between respective walls(871). Cartridge body (870) is coupled with a lower cartridge tray(874). As shown, a vertical slot (849) is formed through part of staplecartridge (868). Three rows of staple apertures (851) are formed throughupper deck (872) on one side of vertical slot (849), with another set ofthree rows of staple apertures (851) being formed through upper deck(872) on the other side of vertical slot (849).

In the present version, cartridge body (870) includes alaterally-opposed pair of upper protrusions (875) extending laterallyoutwardly from opposing sides of cartridge body (870) above tray (874).Likewise, tray (874) includes a laterally-opposed pair of lowerprotrusions (876) extending laterally outwardly from opposing sides oftray (874). Protrusions (875, 876) are configured to abut or otherwiseengage respective side surfaces of channel (39) of lower jaw (16) tothereby horizontally stabilize walls (871) while a wedge sled (notshown), such as any of wedge sleds (41, 110, 210, 310, 410, 510, 610,710) described above, moves longitudinally through staple cartridge(37). For example, protrusions (875, 876) may inhibit laterally outwarddeflection (e.g., bending) of walls (871). In this regard, protrusions(875, 876) of the present version may bias the corresponding walls (871)toward a substantially vertical orientation by counteracting anylaterally-outwardly directed forces that might be applied to walls (871)during use (e.g., clamping and/or firing). In some versions, one or bothupper protrusions (875) may be omitted. In some other versions, one orboth lower protrusions (876) may be omitted.

VI. EXEMPLARY CARTRIDGE HAVING CARTRIDGE TRAY WITH PROTRUSIONS FORDECREASING TISSUE GAP

In some instances, it may be desirable to provide a staple cartridgethat enables a decreased tissue gap between the upper deck of the staplecartridge and the inner surface of anvil (18) having staple formingpockets (53) as compared to staple cartridge (37), to thereby producemore tightly formed staples (47). FIG. 21 shows an exemplary staplecartridge (968) which provides such functionality. Staple cartridge(968) is similar to staple cartridge (37) described above except asotherwise described below. For example, staple cartridge (37) isconfigured to be removably installed into a channel (39) of lower jaw(16).

As shown, staple cartridge (968) of this example includes cartridge body(70), which is coupled with a lower cartridge tray (974). In the presentversion, tray (974) includes a laterally-opposed pair of outerprotrusions (975) extending downwardly from a lower surface of tray(974), and a laterally-opposed pair of inner protrusions (976) extendingdownwardly from the lower surface of tray (974). In some versions,protrusions (975, 976) may each have a height (H) relative to the lowersurface of tray (974) that is greater than a material thickness (T) oftray (974). For example, protrusions (975, 976) may each have a height(H) relative to the lower surface of tray (974) of approximately 0.010inch, while tray (974) may have a material thickness (T) ofapproximately 0.007 inch. Alternatively, any other suitable height ofprotrusions (975, 976) may be used. In any event, protrusions (975, 976)are configured to abut or otherwise engage an upper surface of channel(39) of lower jaw (16) to thereby vertically support tray (974) abovethe upper surface of channel (39) of lower jaw (16). For example,protrusions (975, 976) may increase the height of an upper surface oftray (974) (e.g., along which a wedge sled such as wedge sled (310) maytranslate longitudinally) relative to the upper surface of channel (39)as compared to tray (74) by the height (H) of protrusions (975, 976),thereby also increasing the height of upper deck (72) relative to theupper surface of channel (39) by the height (H) of protrusions (975,976). Thus, upper deck (72) may be spaced apart from the inner surfaceof anvil (18) having staple forming pockets (53) by inside and outsidetissue gaps (Gi, Go) that are respectively less than those provided inthe absence of protrusions (975, 976) by the height (H) of protrusions(975, 976). For example, inside tissue gap (Gi) may be approximately0.04 inch, and/or outside tissue gap (Go) may be approximately 0.055inch. In this manner, staple cartridge (968) may cooperate with anvil(18) to produce staples (47) that are more tightly formed as compared tothose produced by staple cartridge (37), and that may therefore becapable of clamping tissue more tightly than those produced by staplecartridge (37).

VII. EXAMPLES OF COMBINATIONS

The following examples relate to various non-exhaustive ways in whichthe teachings herein may be combined or applied. It should be understoodthat the following examples are not intended to restrict the coverage ofany claims that may be presented at any time in this application or insubsequent filings of this application. No disclaimer is intended. Thefollowing examples are being provided for nothing more than merelyillustrative purposes. It is contemplated that the various teachingsherein may be arranged and applied in numerous other ways. It is alsocontemplated that some variations may omit certain features referred toin the below examples. Therefore, none of the aspects or featuresreferred to below should be deemed critical unless otherwise explicitlyindicated as such at a later date by the inventors or by a successor ininterest to the inventors. If any claims are presented in thisapplication or in subsequent filings related to this application thatinclude additional features beyond those referred to below, thoseadditional features shall not be presumed to have been added for anyreason relating to patentability.

Example 1

A staple driver actuator for a surgical stapler comprises: (a) a basehaving at least one bottom surface, wherein the at least one bottomsurface defines a plane, wherein the at least one bottom surface isconfigured to slide longitudinally relative to a jaw of the surgicalstapler; (b) a plurality of rails extending upwardly from the base,wherein each of the plurality of rails includes at least one camsurface, wherein each of the cam surfaces is inclined relative to theplane, wherein the plurality of rails includes: (i) a laterally-opposedpair of outer rails, and (ii) a laterally-opposed pair of inner rails;and (c) a distal nose extending distally from at least a portion of thebase and having at least one ledge surface, wherein the at least oneledge surface faces upwardly, is parallel to the plane, and is at leastpartially positioned distally relative to each of the outer and innerrails.

Example 2

The staple driver actuator of Example 1, wherein the at least one ledgesurface includes a laterally-opposed pair of ledge surfaces.

Example 3

The staple driver actuator of any one or more of Examples 1 through 2,wherein the distal nose includes an upper portion and a lower portionextending laterally outwardly relative to the upper portion to definethe at least one ledge surface.

Example 4

The staple driver actuator of Example 3, wherein the upper portion is atleast partially positioned distally relative to each of the outer andinner rails.

Example 5

The staple driver actuator of any one or more of Examples 1 through 4,wherein the base includes at least one top surface, wherein the at leastone ledge surface extends distally from the at least one top surface.

Example 6

The staple driver actuator of any one or more of Example 1 through 5,wherein the base includes at least one top surface, wherein the at leastone ledge surface and the at least one top surface are positioned at asame height relative to the plane.

Example 7

The staple driver actuator of any one or more of Examples 1 through 6,wherein the base includes at least one top surface, wherein the at leastone ledge surface is seamlessly contiguous with the at least one topsurface.

Example 8

The staple driver actuator of any one or more of Examples 1 through 7,wherein the distal nose includes a distal tip, wherein the at least oneledge surface extends distally to the distal tip.

Example 9

The staple driver actuator of any one or more of Example 1 through 7,wherein the at least one ledge surface extends distally to at least onedistal cam surface inclined downwardly and distally from the at leastone ledge surface toward a distal tip of the distal nose.

Example 10

The staple driver actuator of any one or more of Examples 1 through 9,wherein the distal nose extends upwardly from the base.

Example 11

The staple driver actuator of any one or more of Examples 1 through 10,wherein the distal nose extends distally from the base.

Example 12

The staple driver actuator of any one or more of Examples 1 through 11,wherein the distal nose includes a distal cam surface inclineddownwardly and proximally from a distal tip of the distal nose towardthe at least one bottom surface.

Example 13

The staple driver actuator of any one or more of Examples 1 through 12,wherein the distal nose is at least partially positioned between theinner rails.

Example 14

The staple driver actuator of Example 13, wherein the distal nose isequally spaced apart from each of the inner rails.

Example 15

An apparatus comprising: (a) a staple cartridge, wherein the staplecartridge includes a cartridge tray and a cartridge body; and (b) thestaple driver actuator of any one or more of Examples 1 through 14,wherein the staple driver actuator is captured between the cartridgetray and the cartridge body such that the at least one ledge surface isconfigured to support at least a portion of the cartridge body.

Example 16

An apparatus comprising: (a) a jaw, wherein the jaw defines alongitudinal axis; (b) an anvil movable relative to the jaw; (c) acartridge, wherein the cartridge is insertable into the jaw, wherein thecartridge comprises: (i) a plurality of walls, and (ii) a plurality ofstaple drivers movable relative to the plurality of walls; and (d) astaple driver actuator disposed within the cartridge, wherein the stapledriver actuator comprises: (i) a laterally-opposed pair of outer railsconfigured to cammingly engage respective staple drivers of theplurality of staple drivers during translation of the staple driveractuator along the longitudinal axis, (ii) a laterally-opposed pair ofinner rails configured to cammingly engage respective staple drivers ofthe plurality of staple drivers during translation of the staple driveractuator along the longitudinal axis, and (iii) a distal nose having atleast one ledge surface, wherein the at least one ledge surface is atleast partially positioned distally relative to each of the outer andinner rails, wherein the at least one ledge surface is configured tosupport at least one wall of the plurality of walls during translationof the staple driver actuator along the longitudinal axis.

Example 17

The apparatus of Example 16, wherein the distal nose includes an upperportion and a lower portion extending laterally outwardly relative tothe upper portion to define the at least one ledge surface.

Example 18

The apparatus of Example 17, wherein the upper portion includes at leastone side surface, wherein the at least one side surface is at leastpartially positioned distally relative to each of the outer and innerrails, wherein the at least one side surface is configured to stabilizethe at least one wall of the plurality of walls during translation ofthe staple driver actuator along the longitudinal axis.

Example 19

The apparatus of any one or more of Examples 16 through 18, wherein theat least one ledge surface includes a laterally-opposed pair of ledgesurfaces, wherein the ledge surfaces are configured to supportcorresponding walls of the plurality of walls during translation of thestaple driver actuator along the longitudinal axis.

Example 20

An apparatus comprising: (a) a jaw, wherein the jaw defines alongitudinal axis; (b) an anvil movable relative to the jaw; (c) acartridge, wherein the cartridge is insertable into the jaw, wherein thecartridge comprises: (i) an elongate slot having a width, and (ii) aplurality of staple drivers movable relative to the elongate slot; and(d) a staple driver actuator disposed within the cartridge, wherein thestaple driver actuator comprises: (i) at least one rail configured tocammingly engage the plurality of staple drivers during translation ofthe staple driver actuator along the longitudinal axis, and (ii) adistal nose having: (A) a lower portion extending to a distal tip of thedistal nose, wherein the lower portion is at least partially positioneddistally relative to the at least one rail, wherein the lower portionhas a first thickness greater than the width of the elongate slot, and(B) an upper portion extending to the distal tip of the distal nose,wherein the upper portion has a second thickness less than or equal tothe width of the elongate slot.

VIII. MISCELLANEOUS

Any one or more of the teachings, expressions, embodiments, examples,etc. described herein may be combined with any one or more of theteachings, expressions, embodiments, examples, etc. described in U.S.Pat. App. No. [Atty. Ref. END9296USNP2], entitled “Surgical Stapler EndEffector Sled Having Staple Driver Support Feature,” filed on even dateherewith; U.S. Pat. App. No. [Atty. Ref. END9296USNP3], entitled“Surgical Stapler End Effector Sled Having Tapered Distal End,” filed oneven date herewith; U.S. Pat. App. No. [Atty. Ref. END9296USNP4],entitled “Surgical Stapler End Effector Sled Having Multiple SurfaceFinishes,” filed on even date herewith; U.S. Pat. App. No. [Atty. Ref.END9296USNP5], entitled “Surgical Stapler End Effector Sled HavingCartridge Biasing Feature,” filed on even date herewith; U.S. Pat. App.No. [Atty. Ref. END9296USDP1], entitled “Surgical Stapler End EffectorSled,” filed on even date herewith; and/or U.S. Pat. App. No. [Atty.Ref. END9296USDP2], entitled “Surgical Stapler End Effector Sled,” filedon even date herewith. The disclosure of each of these applications isincorporated by reference herein.

It should be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those skilled in the art in view of the teachingsherein. Such modifications and variations are intended to be includedwithin the scope of the claims.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.

Versions of the devices described above may be designed to be disposedof after a single use, or they may be designed to be used multipletimes. Versions may, in either or both cases, be reconditioned for reuseafter at least one use. Reconditioning may include any combination ofthe steps of disassembly of the device, followed by cleaning orreplacement of particular pieces, and subsequent reassembly. Inparticular, some versions of the device may be disassembled, and anynumber of the particular pieces or parts of the device may beselectively replaced or removed in any combination. Upon cleaning and/orreplacement of particular parts, some versions of the device may bereassembled for subsequent use either at a reconditioning facility, orby a user immediately prior to a procedure. Those skilled in the artwill appreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that may penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

1-20. (canceled)
 21. A staple driver actuator for a surgical stapler,the staple driver actuator comprising: (a) a base configured to slidelongitudinally relative to a jaw of the surgical stapler; and (b) a noseextending upwardly from the base and having a ledge surface raised abovea top surface of the base, wherein a distal end portion of the stapledriver actuator is configured to lift a portion of a staple cartridgebody onto the ledge surface as the staple driver actuator advancesdistally relative to the jaw, wherein the ledge surface is configured tosupport the portion of the staple cartridge body.
 22. The staple driveractuator of claim 21, wherein the staple driver actuator furthercomprises a tapered surface inclined downwardly and extending distallyfrom a distal end of the ledge surface.
 23. The staple driver actuatorof claim 22, wherein the tapered surface is configured to lift theportion of the staple cartridge body onto the ledge surface.
 24. Thestaple driver actuator of claim 23, wherein the portion of the staplecartridge body comprises an inner wall of the staple cartridge body. 25.The staple driver actuator of claim 21, wherein the ledge surface isrecessed below a top surface of the central nose and extends parallel tothe top surface of the base.
 26. The staple driver actuator of claim 21,wherein the ledge surface protrudes laterally from a side of the nose.27. The staple driver actuator of claim 21, wherein the ledge surfaceincludes a smooth surface finish configured to promote reduced frictionbetween the ledge surface and the staple cartridge body, the smoothsurface finish being smoother relative to another surface of the nose.28. The staple driver actuator of claim 27, further comprising a distaltapered surface inclined downwardly and extending distally from a distalend of the ledge surface, wherein the distal tapered surface includesthe smooth surface finish.
 29. The staple driver actuator of claim 21,wherein the ledge surface is further configured to engage a lowersurface of an inner wall of the staple cartridge body.
 30. The stapledriver actuator of claim 21, wherein the base includes a raised platformconfigured to slidably support the staple cartridge body, wherein theledge surface is seamlessly contiguous with the raised platform andextends distally from the raised platform.
 31. The staple driveractuator of claim 30, wherein the raised platform and the ledge surfaceare configured to slidably support the staple cartridge body withoutlowering or raising the staple cartridge body as the staple driveractuator advances distally relative to the jaw.
 32. The staple driveractuator of claim 21, further comprising a cam surface configured tolift staple drivers housed by the staple cartridge body upwardly as thestaple driver actuator advances distally relative to the jaw, whereinthe cam surface is positioned proximal to the distal end portion of thestaple driver actuator such that the staple driver actuator isconfigured to lift the portion of the staple cartridge body prior tolifting the staple drivers when advanced distally relative to the jaw.33. The staple driver actuator of claim 21, wherein the ledge surfacecomprises a first ledge surface, wherein the nose further includes asecond ledge surface laterally opposed from the first ledge surfaceabout a central axis of the staple driver actuator, wherein each of thefirst ledge surface and the second ledge surface includes a distaltapered surface inclined downwardly and extending distally from a distalend of the respective ledge surface.
 34. An apparatus comprising: (a) astaple cartridge, wherein the staple cartridge includes a cartridge trayand the staple cartridge body; and (b) the staple driver actuator ofclaim 21, wherein the staple driver actuator is captured between thecartridge tray and the staple cartridge body.
 35. An apparatuscomprising: (a) a first jaw, wherein the first jaw defines alongitudinal axis; (b) a second jaw having an anvil and movable relativeto the first jaw to compress tissue; and (c) a staple cartridgeinsertable into the first jaw, wherein the staple cartridge comprises:(i) a cartridge body, (ii) a plurality of staple drivers movable withinthe cartridge body to eject staples into tissue, and (iii) a stapledriver actuator operable to actuate the staple drivers, wherein thestaple driver actuator comprises: (A) a base configured to slidelongitudinally relative to the first jaw, and (B) a central noseextending upwardly from the base, wherein the central nose includes: (1)a ledge surface, wherein the ledge surface is configured to support thecartridge body, and (2) a distal tapered surface inclined downwardly andextending distally from a distal end of the ledge surface, wherein adistal end of the distal tapered surface is raised above a top surfaceof the base, wherein the distal tapered surface is configured to liftthe cartridge body onto the ledge surface as the staple driver actuatoradvances distally relative to the cartridge body.
 36. The staple driveractuator of claim 35, wherein the distal tapered surface is furtherconfigured to lift an inner wall of the cartridge body.
 37. An apparatuscomprising: (a) a first jaw, wherein the first jaw defines alongitudinal axis; (b) a second jaw having an anvil and movable relativeto the first jaw to compress tissue; and (c) a staple cartridgeinsertable into the first jaw, wherein the staple cartridge comprises:(i) a cartridge body, (ii) a plurality of staple drivers movable withinthe cartridge body to eject staples into tissue, and (iii) a stapledriver actuator operable to actuate the staple drivers, wherein thestaple driver actuator comprises: (A) a base configured to slidelongitudinally relative to the first jaw, and (B) a central noseextending upwardly from the base and having an inclined surface, whereinthe inclined surface is configured to lift and support the cartridgebody as the staple driver actuator advances distally relative to thecartridge body.
 38. The apparatus of claim 37, wherein the inclinedsurface is located at a distal end of the central nose, wherein thestaple driver actuator further comprises a ledge surface extendingproximally from the inclined surface, the ledge surface being configuredto support the staple cartridge body.
 39. The apparatus of claim 38,wherein the inclined surface is configured to lift the staple cartridgebody onto the ledge surface.
 40. The apparatus of claim 39, wherein thebase includes a raised platform configured to slidably support thestaple cartridge body, wherein the ledge surface is seamlesslycontiguous with the raised platform and extends distally from the raisedplatform.